Crown Forklift TSP 6000 Series Maintenance Manual by www.heydownloads.com

TSP 6000 SERIES MAINTENANCE MANUAL

M Order Number: 812564-006 Revision: B • Printed in Germany

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

CROWN Gabelstapler GmbH & Co. KG – European Headquarter – Moosacher Str. 52 80809 München Germany Phone +49 (0)89 93 00 2 – 0 Fax +49 (0)89 93 00 2 – 133

TABLE OF CONTENTS

Notes:

TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION

PAGE

SERIAL NO. CUT

REV.

SERIAL NO. CUT

REV.

SERIAL NO. CUT

REV.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SAFETY

PAGE

General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . 7 Cleaning of Material Handling Equipment . . . . . . . . . . . . . . . . 9 Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Lockout - Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Towing Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Towing by Pulling in Power Unit First Direction . . . . . . . . 15 Towing by Pushing in Forks First Direction . . . . . . . . . . . . 16 Lifting and Blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Main Mast, Auxiliary Mast and Platform . . . . . . . . . . . . . . . . . 19 Main Mast - TF & TN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Main Mast - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Blocking Third Stage Mast Above Second Stage Mast . . . 19 Auxiliary Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Platform - TT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Tool Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Spring Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Spring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Auxiliary Mast and Platform Lifting . . . . . . . . . . . . . . . . . . . . . 24 Auxiliary Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Planned Maintenance - Lubricants . . . . . . . . . . . . . . . . . . . . . 25

LUBRICATION & ADJUSTMENT

PAGE

Lubrication and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 31 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Component Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Componentry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

TSP 6000 Series

III

TABLE OF CONTENTS Audible Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ALM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 ALM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 HN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 BATT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 ED1, ED2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Encoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ECR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ECR2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ECR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ECR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 ECR5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 ECR6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 ECR7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 ECR8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FU4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FU5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 FU6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 FU7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 FU8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 FU9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 FU10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 FU11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FU12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FU13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FU14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FU15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FU16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FU17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FU18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FU19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FU20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 FU21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 LGT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 LGT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 LGT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 LGT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 LGT5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 LGT 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 LGT 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 LGT8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 LGT9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

TSP 6000 Series

TABLE OF CONTENTS Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 BRK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 EAC Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FAN1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FAN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FSB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 FSB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 JC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 P1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 PS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 PS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ACCESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ACCESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ACCESS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 ACCESS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ACCESS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ACCESS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 ACCESS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 M2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 M3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 POT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 POT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 POT3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 POT4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 POT5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 K1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 RES1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 RES2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 RES3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 RES4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 RES5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 CS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 EACA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 EACA2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 EACB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 EACB2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 GS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 GS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 TS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 TS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

TSP 6000 Series

TABLE OF CONTENTS Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 EML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 MVL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 PCML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 PVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 PVAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 PVF1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 PVF2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 PVLH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 PVML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 PVMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 PVP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 PVP2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 PVT1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 PVT2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 SP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 SVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 SVML . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Suppressor Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 SB11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 SB31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 SB41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 APS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 BRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 BRS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 BRS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 BRS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 BRS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 CHS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 CHS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 CHS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 CHS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 CHS5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 CHS6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 CHS7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 CHS8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 CTS (TF Mast Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 DTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 EDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 EMS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 EMS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 FHSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 FHSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 FNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 FPS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 FPS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 FPS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 FPS4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 FPS5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 FPS6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 FPS7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 FPS8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 FPS9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 TSP 6000 Series

TABLE OF CONTENTS FS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 GTSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 GTSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 GUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 HCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 HGTRS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 HGTRS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 HNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 HPSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 HPSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 KYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 LGS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 LGS2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 LGS3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 ORS1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 PRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 RGSL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 RGSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 RS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 RSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 SES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 SLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 TBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 TDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 TVRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 ZSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Metric Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

HYDRAULIC SYSTEM

PAGE

SERIAL NO. CUT

REV.

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Hydraulic Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 117 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Lift Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Freezer Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Main Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Main Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Main Lower Circuit (MVL) . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Load Handler Circuit through Main Frame Manifold . . . . . . 123 Auxiliary Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Auxiliary Lower Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Traverse Left Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Traverse Right Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Fork Extend Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Fork Retract Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Pivot Right Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Pivot Left Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 TSP 6000 Series

VII

TABLE OF CONTENTS Hydraulic Schematic Symbols . . . . . . . . . . . . . . . . . . . . . . . . 138 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Initial Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Relief Valve (RV1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Proportional Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Manifold Block O-Ring Replacement . . . . . . . . . . . . . . . . . . 145 Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Preparation Before Disassembly . . . . . . . . . . . . . . . . . . . . . 147 Tools and Materials Required for Servicing . . . . . . . . . . . . . 147 Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 149 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

DRIVE UNIT

PAGE

SERIAL NO. CUT

REV.

SERIAL NO. CUT

REV.

Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Drive Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Lathe Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Drive Unit Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Drive Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Drive Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Drive Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 Drive Motor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

ELECTRICAL SYSTEM

PAGE

ACCESS 123® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 When a Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . . . 173 Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Software Package Version Level . . . . . . . . . . . . . . . . . . . . . 173 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Analyzer Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Input Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Platform Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Seat Controls Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Power Unit Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Outputs Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Load Handler Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Platform Menu or Seat Controls Menu . . . . . . . . . . . . . . . . . 189 Power Unit Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Test Outputs Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194 Load Handler Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195 Platform Menu or Seat Controls Menu . . . . . . . . . . . . . . . . . 196 Power Unit Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Calibration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Handles Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Hydraulics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Pivot Sense Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 Main R Valve Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 Main L Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Main HGT Sense Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 Aux Flow Valve Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207 Traverse Valve Menu or Pivot Valve Menu . . . . . . . . . . . . . . 208 TSP 6000 Series

VIII

TABLE OF CONTENTS Extend Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 Aux R Valve Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 Weight Sense Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 Aux Valve Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 Aux HGT Sense Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Tilt Valve Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Height Cutouts Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Steer Encoder Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216 Wire Guide Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Calibrate Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 Adjust X-Offset Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Features Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Mast Type, Measurement, Collapsed Height , Lift Height or Traverse Frame Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Fork Type Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 Fork Length, Pallet Width, Pallet Length or Battery Compartment Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226 Truck Weight, Max Load or Lift Motor Menu . . . . . . . . . . . . 227 Capacity Data Monitor Menu . . . . . . . . . . . . . . . . . . . . . . . . 228 Wire Guidance or Manual Wire Sense Menu . . . . . . . . . . . . 229 End Aisle, Battery Retainer SW or Travel Alarm Menu . . . . 230 Language or User Performance Menu . . . . . . . . . . . . . . . . . 231 User Codes or Cold Condition Menu . . . . . . . . . . . . . . . . . . 232 Options Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 Front Rail, Zone Switch, Aux Mast, Screen Setup or Save Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235 Hour Meters Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 Event Codes Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 Performance Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 P1 Setup P1 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 P2 Setup P2 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 P3 Setup P3 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243 Plug, Coast, Braking or Free Range Speeds Menu . . . . . . . 245 Guided Speeds Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 EAC Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 Main Hoist R or L Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Aux Hoist R or L Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 PDS Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 Utilities Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252 Active Tow Mode, Shipping Mode, Truck lockout or Traverse Valve Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 Wire Guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Line Driver Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256 Field Strength Cross Reference Chart . . . . . . . . . . . . . . 257 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258 End Aisle Control (EAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Wire Guidance Calibration Speeds . . . . . . . . . . . . . . . . . . . 260 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 Termination Point Locations . . . . . . . . . . . . . . . . . . . . . . . . . 261 TSP 6000 Series

TABLE OF CONTENTS Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262 Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269 Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 ACCESS Module Listing: . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Some Troubleshooting Basics . . . . . . . . . . . . . . . . . . . . . 270 When a Malfunction Occurs . . . . . . . . . . . . . . . . . . . . . . . 270 No Event Code? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 To Locate Malfunctioning Components . . . . . . . . . . . . . . 270 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270 Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . 270 Event Codes - ACCESS 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Event Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 Event Code 104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Event Code 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273 Event Code 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Event Code 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Event Code 108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Event Code 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Event Code 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Event Code 114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Event Code 115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Event Code 116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Event Code 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Event Code 118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277 Event Codes - ACCESS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Event Code 212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Event Code 213 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Event Code 214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Event Code 215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Event Code 216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Event Code 217 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Event Code 218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Event Code 221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Event Code 222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Event Code 223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Event Code 224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Event Code 225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 Event Code 228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 TSP 6000 Series

TABLE OF CONTENTS Event Code 229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 Event Code 231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282 Event Code 232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Event Code 233 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283 Event Code 234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Event Code 235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286 Event Code 236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 Event Code 237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 Event Code 246 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Event Code 247 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Event Code 249 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Event Code 251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Event Code 255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Event Code 256 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288 Event Code 268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Event Code 269 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Event Code 272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289 Event Code 273 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 Event Code 278 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290 Event Codes - ACCESS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Event Code 300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Event Code 312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Event Code 313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Event Code 315 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Event Code 317 and 318 . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Event Code 321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Event Code 322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Event Code 323 and 324 . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Event Code 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 Event Code 326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 Event Code 327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 Event Code 328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Event Code 329 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Event Code 331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Event Code 332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 Event Code 333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297 Event Code 334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 Event Code 336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 Event Code 337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Event Code 346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Event Code 347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Event Code 349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Event Code 351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Event Code 368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Event Code 369 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Event Code 372 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300 Event Code 373 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Event Code 378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Event Codes - ACCESS 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Event Code 400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Event Code 402 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Event Code 403 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304 Event Code 407 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Event Code 408 and 409 . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 TSP 6000 Series

TABLE OF CONTENTS Event Code 411 and 430 . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Event Code 436 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Event Code 437 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Event Code 438 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Event Code 439 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Event Code 440 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Event Code 441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Event Code 442 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Event Code 443 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Event Code 444 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310 Event Code 445 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Event Code 446 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Event Code 447 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Event Code 491 Through Event Code 499 . . . . . . . . . . . . . . 313 Event Codes - ACCESS 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Event Code 501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Event Code 502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Event Code 503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Event Code 504 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Event Code 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Event Code 507 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Event Code 508 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Event Code 509 and 510 . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Event Code 511 Through Event Code 521 . . . . . . . . . . . . . . 318 Event Code 522 and 523 . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Event Code 524 and 525 . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Event Code 526 and 527 . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Event Code 528 and 529 . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Event Code 530 and 531 . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 Event Code 532 and 533 . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 Event Code 534 and 535 . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 Event Code 536 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Event Code 537 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Event Code 538 and 539 . . . . . . . . . . . . . . . . . . . . . . . . . . . 323 Event Code 540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Event Code 541 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Event Code 542 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Event Code 543 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Event Code 544 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Event Code 545 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Event Code 546 Through Event Code 550 . . . . . . . . . . . . . . 326 Event Code 551 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Event Code 552 and 553 . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Event Code 554 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Event Code 555 and 556 . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Event Code 557 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328 Event Code 558 Through Event Code 561 . . . . . . . . . . . . . . 329 Event Code 562 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Event Code 563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Event Code 564 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Event Code 565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Event Code 566 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331 Event Code 567 Through Event Code 570 . . . . . . . . . . . . . . 332 Event Code 571 and 572 . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 TSP 6000 Series

XII

TABLE OF CONTENTS Event Code 576 Through Event Code 581 . . . . . . . . . . . . . 333 Event Code 582 Through Event Code 585 . . . . . . . . . . . . . 333 Event Code 586 and 587 . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 Event Code 588 and 589 . . . . . . . . . . . . . . . . . . . . . . . . . . . 335 Event Code 590 and 591 . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Event Code 592 and 593 . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Event Code 594 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336 Event Code 595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 Event Code 596 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 Event Code 597 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 Event Codes - ACCESS 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Event Code 605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Event Code 611, 612 and 621 Through Event Code 628 . . 339 Event Code 631 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Event Code 632 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Event Code 633 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 Event Code 636 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Event Code 637 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Event Code 638 and 639 . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Event Code 652 Through Event Code 659 . . . . . . . . . . . . . 342 Event Code 660 Through Event Code 663 . . . . . . . . . . . . . 343 Event Code 664 Through Event Code 667 . . . . . . . . . . . . . 343 Event Code 668 Through Event Code 671 . . . . . . . . . . . . . 343 Event Code 672 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344 Event Codes - ACCESS 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Event Code 700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Event Code 701 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Event Code 702 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347 Event Code 707 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 Event Code 708 and 709 . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Event Code 711 Through Event Code 720 . . . . . . . . . . . . . 350 Event Code 736 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Event Code 737 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Event Code 738 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Event Code 739 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Event Code 740 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Event Code 741 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 Event Code 742 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353 Event Code 743 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Event Code 744 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354 Event Code 745 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 Event Code 746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 Event Code 747 Through Event Code 749 . . . . . . . . . . . . . 356 Event Code 750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356 Event Code 751 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Event Code 752 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 Event Code 753 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359 Event Code 754 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360 Event Code 755 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 Event Code 756 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362 Event Code 757 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 Event Code 758 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 Event Code 759 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 Event Code 760 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 TSP 6000 Series

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TABLE OF CONTENTS Event Code 761 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 Event Code 762 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 Event Code 763 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366 Event Code 764 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 Event Code 765 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367 Event Code 767 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 Event Code 768 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368 Event Code 769 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 Event Code 770 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369 Event Code 771 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 Event Code 772 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 Event Code 773 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370 Event Code 774 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 Event Code 775 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371 Event Code 776 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 Event Code 777 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372 Event Code 778 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 Event Code 779 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373 Event Code 780 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 Event Code 781 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375 Event Code 782 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 Event Code 783 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 Event Code 784 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 Event Code 785 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 Event Code 790 Through Event Code 799 . . . . . . . . . . . . . . 378 Event Codes - ACCESS 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379 Event Code 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379 Event Code 801 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379 Event Code 802 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 Event Code 803 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381 Event Code 804 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382 Event Code 805 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383 Event Code 806 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384 Event Code 807 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385 Event Code 816 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 Event Code 821 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 Event Code 822 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386 Event Code 823 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Event Code 824 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Event Code 825 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 Event Code 836 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388 Event Code 837 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 Event Code 838 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389 Event Code 839 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 Event Code 840 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391 Event Code 841 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392 Event Code 842 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392 Event Code 843 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393 Event Code 844 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393 Event Code 845 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393 Event Code 846 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 Event Code 847 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 Event Code 848 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 Event Code 849 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397 TSP 6000 Series

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TABLE OF CONTENTS Event Code 850 Through Event Code 852 . . . . . . . . . . . . . 399 Event Code 853 Through Event Code 855 . . . . . . . . . . . . . 399 Event Code 856 Through Event Code 859 . . . . . . . . . . . . . 400 Event Code 860 Through Event Code 863 . . . . . . . . . . . . . 400 Event Code 864 Through Event Code 867 . . . . . . . . . . . . . 401 Event Code 868 and 869 . . . . . . . . . . . . . . . . . . . . . . . . . . . 401 Event Code 870 and 871 . . . . . . . . . . . . . . . . . . . . . . . . . . . 402 Event Code 872 Through Event Code 874 . . . . . . . . . . . . . 403 Event Code 875 Through Event Code 877 . . . . . . . . . . . . . 404 Event Code 878 Through Event Code 880 . . . . . . . . . . . . . 406

BRAKE SYSTEM

PAGE

SERIAL NO. CUT

REV.

SERIAL NO. CUT

REV.

SERIAL NO. CUT

REV.

Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Brake Force Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Torque Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409 Air Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411 Rotor and Brake Pad Replacement . . . . . . . . . . . . . . . . . . . 412 To disassemble rotor and brake pad assembly: . . . . . . . 412 Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

STEERING

PAGE

Steering Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 Replacing Steering Feedback Assembly Encoder . . . . . . . . 417 Replacing Steering Feedback Assembly Gears . . . . . . . . . 418 Steering Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Steering Motor Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Replacing Steering Motor Brushes . . . . . . . . . . . . . . . . . 420 Replacing Steering Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Steering Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422 Replacing Steering Gearbox . . . . . . . . . . . . . . . . . . . . . . . . 422

LIFTING MECHANISM

PAGE

Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 TN (Telescopic No Free Lift) Mast . . . . . . . . . . . . . . . . . . . . 427 TF (Telescopic Full Free Lift) Mast . . . . . . . . . . . . . . . . . . . . 427 TT (Triple Telescopic Full Free Lift) Mast . . . . . . . . . . . . . . . 427 New Truck Assembly Procedures . . . . . . . . . . . . . . . . . . . . 427 To Assemble Power Unit, Mainframe and Platform and Load Handler: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 Second Stage Mast Removal TF and TN . . . . . . . . . . . . . . 431 Removing Second Stage Mast TF and TN . . . . . . . . . . . . . 431 Removing Second Stage Mast TF and TN . . . . . . . . . . . . . 435 Removing Second and Third Stages from TT Mast Assembly435 Roller Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 Column Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443 Side Thrust Rollers TF and TN . . . . . . . . . . . . . . . . . . 443 Installing Second Stage Mast TF and TN . . . . . . . . . . . . . . 443 Installing Second Stage Mast TF and TN . . . . . . . . . . . . . . 445 Installing Second and Third Stage TT Mast . . . . . . . . . . . . . 446 Hose Take-Up Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451

TSP 6000 Series

TABLE OF CONTENTS Load Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 Load Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 Lathe Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455 Rust and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 Cracked Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 Tight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Protruding or Turned Pins . . . . . . . . . . . . . . . . . . . . . . . . 457 Chain Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457 Lift Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 458 Chain Anchors and Pulleys . . . . . . . . . . . . . . . . . . . . . . . 459 Leaf Chain Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . 459 Disconnect Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 459 Fork Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 Blade Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 Hanger Bore Measurement . . . . . . . . . . . . . . . . . . . . . . . 461 Overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 Bent or Twisted Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 463 Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464

CYLINDERS

PAGE

TF Lift Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467 Pivoting The Tip-Out Assembly . . . . . . . . . . . . . . . . . . . . . . . 467 Primary (Free) Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . 470 Cylinder Packing Installation . . . . . . . . . . . . . . . . . . . . . . . . . 472 Reassembling Mast Tip-Out . . . . . . . . . . . . . . . . . . . . . . . . . 473 Primary (Free) Lift Cylinder Removal . . . . . . . . . . . . . . . . . . 474 Secondary (Main) Lift Cylinder Removal . . . . . . . . . . . . . . . 475 Primary (Free) Lift Cylinder Installation . . . . . . . . . . . . . . . . . 476 Secondary (Main) Lift Cylinder Installation . . . . . . . . . . . . . . 476 Lift Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477 TN Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 478 Pivoting the Tip-Out Assembly . . . . . . . . . . . . . . . . . . . . . . . 478 Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480 Cylinder Packing Installation . . . . . . . . . . . . . . . . . . . . . . . . . 482 Reassembling Mast Tip-Out . . . . . . . . . . . . . . . . . . . . . . . . . 482 Lift Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483 Lift Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484 Lift Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485 Auxiliary Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486 Auxiliary Lift Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . 486 Rod Packing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489 Auxiliary Lift Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . 489 Fork Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490 Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491 Piston Rod Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492 Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492

TSP 6000 Series

XVI

SERIAL NO. CUT

REV.

TABLE OF CONTENTS Pivot Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494 Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494 Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495 Cylinder Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496 Cylinder Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498 Pivot Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498

PLATFORM

PAGE

SERIAL NO. CUT

REV.

SERIAL NO. CUT

REV.

SERIAL NO. CUT

REV.

Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Column Roller Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Overhead Guard Area . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Operator Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Lower Platform Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502 Mast Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503 Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504 GTSL & GTSR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505 Gate Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505 Chain Anchor and Platform Height Adjustment . . . . . . . . . . 505 Side Thrust Roller Adjustment - Platform (TF, TN and TT Mast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506 Traverse Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . 506 Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508 Platform Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511 Seat Pivot Bearing Assembly . . . . . . . . . . . . . . . . . . . . . 512 Seat Rotate Switch Adjustment . . . . . . . . . . . . . . . . . . . 513 Seat Coil Cord Installation . . . . . . . . . . . . . . . . . . . . . . . 514 Seat Up/Down Switch Adjustment . . . . . . . . . . . . . . . . . 515 Mirror Installation And Adjustment . . . . . . . . . . . . . . . . . 516 Mirror Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 518 Height Sensing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 Height Sensor Assembly Removal . . . . . . . . . . . . . . . . . . . 519 Height Sensor Assembly Installation . . . . . . . . . . . . . . . . . . 520 Height Cable Broken Switch (HCS) . . . . . . . . . . . . . . . . . . . 520 Height Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 521 Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521

GLOSSARY

PAGE

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 525

SCHEMATIC DIAGRAMS

PAGE

Introduction to Diagram Usage . . . . . . . . . . . . . . . . . . . . . . . 533 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533 Pictorials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533 Electrical Diagrams Index . . . . . . . . . . . . . . . . . . . . . . . . . . . 534 Platform Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535 Power Unit Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536 Platform Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 537 Platform Distribution Panel w/InfoLink . . . . . . . . . . . . . . . . . 538 Power Unit Distribution Panel . . . . . . . . . . . . . . . . . . . . . . . . 539 Lights And Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 ACCESS 1 Operator Display . . . . . . . . . . . . . . . . . . . . . . . . . 541 TSP 6000 Series

XVII

TABLE OF CONTENTS Platform Chain Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542 ACCESS 4 Vehicle Control Module . . . . . . . . . . . . . . . . . . . . 543 Platform Seat Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544 Platform Floor Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545 ACCESS 3 Traction Control Module . . . . . . . . . . . . . . . . . . . . 546 ACCESS 5 Steering Control Module . . . . . . . . . . . . . . . . . . . 547 Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548 Traction Motor, ECR6, ECR7, FSB1 & Brake . . . . . . . . . . . . . 549 ACCESS 2 Hydraulic Control Module . . . . . . . . . . . . . . . . . . 550 Hydraulic Motor, ECR8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551 ACCESS 8 Operator Control Module . . . . . . . . . . . . . . . . . . . 552 Platform Left Armrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553 ACCESS 6 Guidance Control Module . . . . . . . . . . . . . . . . . . 554 ECR7, FSB1, FSB2 & PDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555 ACCESS 7 Accessory Control Module . . . . . . . . . . . . . . . . . . 556 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558

HYDRAULIC SCHEMATIC

PAGE

Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563

TSP 6000 Series

XVIII

SERIAL NO. CUT

REV.

INTRODUCTION

Notes:

INTRODUCTION Introduction

Introduction

Service Training

This manual is intended for the service technician who is seeking information about maintenance and service replacement parts. It contains a section on troubleshooting which will enable a qualified technician to locate and solve problems which may occur.

Complete Service Training is available for the lift truck technician covering all Crown Lift Trucks, module systems, wire guidance, hydraulic and electrical systems. To obtain more information concerning service training, contact your Crown Dealer or under Training on crown.com.

Operator Instructions This manual does not contain operator instructions. Operator Instructions in tag or booklet form are sent with each truck. Additional copies can be ordered if required. These booklets are for you and your personnel to insure years of safe, trouble-free operation of your Crown Lift Truck. For turret stockpicker operator instructions, refer to Crown publication, TSP 6000 Operator Manual.

Operator Training Crown produces a complete series of operator training programs available through your local Crown dealer. A complete listing of these and other available programs can also be found under Training on crown.com.

Replacement Parts When ordering replacement parts from this manual, always specify, along with the part number, model and serial number of the truck. This information will further enable us to give correct, fast and efficient service. For current part numbers of service manuals, operator manuals, operator training programs, truck capacities and technical specifications, contact your local dealer or at www.crown.com. This manual is arranged according to major sections covers maintenance and replacement parts. The sectional descriptions are as follows:

MAINTENANCE

REPLACEMENT PARTS

SECTION

DESCRIPTION

SECTION

DESCRIPTION

Lubrication and Adjustment

Power Unit Parts

Hydraulic

Hydraulic Parts

Drive Unit

Drive Unit Parts

Electrical

Electrical Parts

Brake

Brake Parts

Steering

Steering Parts

Lifting Mechanism

Lifting Mechanism Parts

Cylinders

Cylinder Parts

Platform

Platform Parts

M10

Glossary

Labels and Decals

Crown 2006 PF15292-1 Rev. 3/09

TSP 6000 Series

ITD-1961-001 01 Rev. 3/09

INTRODUCTION Introduction The truck data number provides you and your Crown dealer with a wealth of information to insure selection of proper parts for your Crown truck. You may simply provide this number to your Crown dealer, or use the Guidance System - = No Guidance System 1 = Wire 2 = Rail 3 = Wire/Rail

End Aisle Control (EAC) - = No EAC N = EAC North Sensing S = EAC South Sensing

following breakdown if selecting your own part numbers or service information from this manual.

Battery Compartment Size AA 550 mm (21.7 in) Hydraulic Performance A 634 mm (25.0 in) S = Standard B 721 mm (28.4 in) H = High C 864 mm (34.0 in) Load Handler Length 584, 686 Thru 1372 mm (23, 27 Thru 54 in) In 76.2 mm (3.0 in) Increments

Voltage 48 = 48 V Mast Type TN = No Telescopic Free Lift TF = Telescopic Full Free Lift TT = Triple Telescopic Full Free Lift

Fork Type T = Telescopic 4 = Fixed 102 mm (4.0 in) Offset 5 = Fixed 127 mm (5.0 in) Offset 6 = Fixed 152 mm (6.0 in) Offset

C TN 207 48 - 01 N 56 B H 27 52 T Traverse Frame Width 1220 Thru 1753 mm (48 Thru 69 in) In 25.4 mm (1.0 in) Increments

Standard/Custom/Special - = Standard C = Custom S = Special

Load Wheel Overall Width (OAW) Value

Lift Height

Guide Wheel Spread (Beyond Load Wheel OAW)

193 =

4902 mm (193 in)

363 =

9220 mm (363 in)

Dash

207 =

5258 mm (207 in)

375 =

9225 mm (375 in)

None

219 =

5563 mm (219 in)

387 =

9830 mm (387 in)

231 =

5868 mm (231 in)

399 =

10135 mm (399 in)

243 =

6172 mm (243 in)

411 =

10440 mm (411 in)

255 =

6477 mm (255 in)

423 =

267 =

6781 mm (267 in)

279 =

Dash

mm (in)

31.75 (1.25)

133.35 (5.25)

38.10 (1.50)

139.70 (5.50)

44.45 (1.75)

146.00 (5.75)

10744 mm (423 in)

50.80 (2.00)

152.40 (6.00)

435 =

11049 mm (435 in)

57.15 (2.25)

158.75 (6.25)

7087 mm (279 in)

447 =

11354 mm (447 in)

63.50 (2.50)

165.10 (6.50)

291 =

7391 mm (291 in)

459 =

11659 mm (459 in)

69.85 (2.75)

171.45 (6.75)

303 =

7696 mm (303 in)

471 =

11963 mm (471 in)

76.20 (3.00)

177.80 (7.00)

315 =

8001 mm (315 in)

483 =

12268 mm (483 in)

82.55 (3.25)

184.15 (7.25)

327 =

8305 mm (327 in)

495 =

12573 mm (495 in)

88.90 (3.50)

190.50 (7.50)

339 =

8611 mm (339 in)

SPC =

Special

95.25 (3.75)

196.85 (7.75)

351 =

8915 mm (351 in)

101.60 (4.00)

203.20 (8.00)

107.95 (4.25)

209.55 (8.25)

114.30 (4.50)

215.90 (8.50)

120.65 (4.75)

222.25 (8.75)

127.00 (5.00)

Note: To determine Collapsed Height, divide the height by 2 and add 546 mm (21.5 in)

ITD-1961-002 01 Rev. 3/09

TSP 6000 Series

mm (in)

Crown 2006 PF15292-2 Rev. 3/09

SAFETY

Notes:

SAFETY General Maintenance Instructions

General Maintenance Instructions WARNING To prevent serious risk of injury to yourself and others observe the following safety instructions. Power industrial trucks may become hazardous if adequate maintenance is neglected. Therefore, adequate maintenance facilities, trained personnel and procedures should be provided. Maintenance and inspection shall be performed in conformance with the following practices: 1. A scheduled planned maintenance, lubrication, and inspection system should be followed. 2. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect truck. 3. Before leaving the truck—

–

Be in operating position.

–

Apply brake.

–

Place directional control in neutral.

–

Before operating truck, check functions of lift systems, directional control, speed control, steering, warning devices, brakes and any attachments if any used.

6. Avoid fire hazards and have fire protection equipment present. Do not use an open flame to check level, or for leakage of electrolyte and fluids or oil. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. 7. Keep shop well ventilated, clean and dry. 8. Brakes, steering mechanisms, control mechanisms, lift overload devices, guards, and safety devices shall be inspected regularly and maintained in a safe operating condition. –

–

Stop truck.

–

Fully lower the load engaging means.

–

Place directional controls in neutral.

–

Apply the parking brake.

–

Turn off power (power disconnect).

–

Remove key.

–

Block the wheels if truck is on an incline.

All guards must be installed to factory configuration and condition before operating truck. Do not operate truck if any guards or fasteners are damaged, improperly installed or missing.

9. Capacity, operation and maintenance instruction plates or decals shall be maintained in legible condition.

4. Before working on truck— –

Raise drive wheel free of floor or disconnect power sources.

–

Use chocks or other positive positioning devices.

–

Block load engaging means, inter masts, or chassis before working under them.

–

Operation to check performance of truck or attachments shall be conducted in an authorized safe clearance area.

Crown 1976 PF2821-1 Rev. 10/08

5. Before starting to operate truck—

10. All parts of lift mechanisms shall be inspected to maintain them in safe operating condition. 11. All hydraulic systems shall be regularly inspected and maintained in conformance with good practice. Cylinders, valves, and other similar parts shall be checked to assure that “drift” has not developed to the extent that it would create a hazard. 12. Batteries, motors, controllers, limit switches, protective devices, electrical conductors, and connections shall be maintained in conformance with good practice. Special attention shall be paid to the condition of electrical insulation. 13. Trucks shall be kept in a clean condition to minimize fire hazards and facilitate detection of loose or defective parts.

TSP 6000 Series

MA-04.0-001 05 Rev. 10/08

SAFETY General Maintenance Instructions 14. Modifications and additions which affect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation and maintenance plates or decals shall be changed accordingly. –

Adding electrical devices (radio, terminal, lights, etc.) or changing existing components or wiring can affect truck operation and could cause an accident. Contact authorized Crown personnel before adding to or changing the electrical system in any way.

–

For EE rated trucks, adding electrical devices could cause a fire or explosion, as well as void the EE rating. Written approval must be obtained from Crown prior to adding electrical device(s). Prior to use, inspection of installed device(s) must be performed by an appropriate nationally recognized testing laboratory (i.e. Underwriters Laboratories Inc) or the Authority Having Jurisdiction (see NFPA 505).

15. Care shall be taken to assure that all replacement parts are interchangeable with the original parts and of equal quality to that provided in the original equipment. 16. Be sure that any equipment added to the truck (terminal, fan, clipboard, etc.) is positioned so that it does not block your vision or interfere with safe and efficient operation of the truck. For further information pertaining to operating and maintenance procedures:

•

All trucks except Series B and Tow Tractors, refer to current ASME B56.1.

•

Series B trucks, refer to current ASME B56.10.

•

Tow Tractors, refer to current ASME B56.9.

MA-04.0-002 05 Rev. 10/08

TSP 6000 Series

Crown 1976 PF 2821-2 Rev. 10/08

SAFETY Cleaning of Material Handling Equipment

Cleaning of Material Handling Equipment Cleaning Methods The preferred method of cleaning built up dirt and dust from electric material handling equipment is dry pressured air. For localized degreasing, use of an appropriate solvent is recommended. If these methods are not effective and power washing is the only alternative, extreme care must be exercised. Electrical components including connectors, terminal boards and wiring can be permanently damaged from water or cleaning solvents. Mineral and chemical residue left on or in components (i.e., circuit boards, contactors, encoders, switches, potentiometers, etc.) after washing is a proponent of oxidation and corrosion.

Functional integrity of contaminated components may be questionable. Nuisance fault logging, intermittent operation or immediate failure could be the resultant of power washing. For these reasons all electronic components including motors must be protected. Component removal is the best method to eliminate the risk of damage. Power washing will also remove or destroy lubricants in or on the surface of shafts, unsealed bearings, hinges, exposed gears, bushings, chains, linkages, etc. These Items must also be protected or properly lubricated after cleaning. Consideration must also be given to metal surfaces. The cleaning process can strip away paint and protective coatings applied to components (i.e., hydraulic lines, terminal strips, linkages) for freezer corrosion environment. Paint or protective coating must be reapplied to these areas to reduce the chance of oxidation and corrosion. Before installing removed components, lubricating or returning the equipment to service it must be free of solvent residue and thoroughly dry.

Crown Cleaning Products

Crown 2005 PF15082-1 Rev. 2/09

Cleaner Type

Part No.

Package Qty.

Degreaser and Cleaner

363105-001 363105-012

20 Oz. Can (12) 20 Oz. Cans

All Purpose Cleaner

363114-001 363114-012

20 Oz. Can (12) 20 Oz. Cans

Glass Cleaner

363101-001 363101-012

20 Oz. Can (12) 20 Oz. Cans

Waterless Hand Cleaner

363111-001 363111-012

15 Oz. Tube (12) 15 Oz. Tubes

Pumiced and Smooth Hand Cleaner

363112-001 363112-012

1 Gallon Jug (4) 1 Gallon Jugs

Wall Mounted Deluxe Soap Dispenser

363122

1 - Used With 363112-004

Tough On Grease

063009-005

1 Gallon Jug

TSP 6000 Series

MA-1960-050 01 Rev. 2/09

SAFETY Control of Hazardous Energy

Control of Hazardous Energy Lockout/Tagout In the interest of safety and to ensure compliance with OSHA Regulations, (Standards - 29 CFR), control of hazardous energy (lockout/tagout) - 1910.147, Crown has developed guidelines for proper energy control when performing service and maintenance on the truck. Before performing any service or maintenance on the truck, review the appropriate sections in this service manual for additional procedures to be followed. In addition, Crown recommends that all mechanics wear appropriate protective items, such as safety glasses, work gloves, and steel-toed shoes, whenever performing service or maintenance work on Crown equipment.

•

Do not allow dirt, cleaning solution or other foreign material to enter cells. Impurities in electrolyte has a neutralizing effect reducing available charge.

•

If battery repair is planned, follow the battery manufacturer's instructions concerning repair practices and procedures.

Battery Care CAUTION Only qualified and experienced personnel should perform maintenance and repair on batteries.

•

Make certain the charger being used matches the voltage and amperage of the truck battery. This voltage is listed on the truck serial plate.

•

Before disconnecting or connecting batteries to a charger, make sure charger is OFF. If an attempt is made to do this while charger is ON, serious injury to you, the battery and charger could result.

•

Never use a match or lighter. Battery fumes are explosive.

•

Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery.

Battery Safety Rules

•

Wear protective clothing, such as, rubber apron, gloves, boots and full-face shield when performing any maintenance on batteries. Do not allow electrolyte to come in contact with eyes, skin, clothing or floor. If electrolyte comes in contact with eyes, flush immediately and thoroughly with clean water. Obtain medical attention immediately. Should electrolyte be spilled on skin, rinse promptly with clean water and wash with soap. A baking soda solution (one pound to one gallon of water) will neutralize acid spilled on clothing, floor or any other surface. Apply solution until bubbling stops and rinse with clean water.

•

Keep vent plugs firmly in place at all times except when adding water or taking hydrometer readings.

•

Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery is charging, is highly explosive. This gas remains in the cells long after charging has stopped.

•

Do not lay metallic or conductive objects on battery. Arcing will result.

MA-1960-100 02 Rev. 4/09

Charging CAUTION Never smoke or bring flame near the battery. Gas formed during charging is highly explosive and can cause serious injury. Consult the charger manufacturer's manual covering your charger for hints on operation and maintenance.

TSP 6000 Series

Crown 2005 PF15064-1 Rev. 4/09

SAFETY Control of Hazardous Energy •

Battery Removal CAUTION

•

When removing the battery, move truck to area intended for battery care. Floor must be level. • Turn key switch or toggle switch to OFF position and remove key. • Disconnect battery and lockout or tagout truck as described in Lockout - Tagout in this section. Never move battery partially from truck without roller stand in place. • Lower load engaging means completely.

• •

If battery is removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Do not allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, transporting the battery. Use an insulator (such as plywood) to cover the top of the battery before and during removal.

If battery was removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Do not allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when transporting or installing the battery. Use an insulator (such as plywood) to cover the top of the battery before and during installation.

CAUTION Make certain battery used meets weight, size and voltage requirements of truck (refer to serial plate). NEVER operate truck with an undersized battery.

Lockout - Tagout Always turn key switch to OFF, remove key and apply tag to steering wheel with cable tie warning others truck is being serviced.

Figure 12723

When maintenance is to be performed and the battery will be left in the truck, disconnect battery, remove the main power fuses and install a commercially available lockout device on the battery connector.

Figure 8251

Battery Installation

When maintenance is performed and the battery is removed from the truck, remove main power fuses, install a lockout device on the trucks battery connector if possible, or if possible install a tag with a cable tie on the trucks battery connector so it cannot be removed easily warning that the truck is not available for operation.

CAUTION When installing the battery, move truck to area intended for battery care. Floor must be level. • Turn key switch or toggle switch to OFF position and remove key. • Lockout or tagout truck as described in Lockout Tagout in this section.

Crown 2005 PF15064-2 Rev. 4/09

TSP 6000 Series

MA-1960-101 02 Rev. 4/09

SAFETY Control of Hazardous Energy Capacitance Due to capacitance voltage present in the traction motor controller and lift motor controller, whenever performing maintenance which may permit contact with the bus bars and associated power cables, discharge the capacitors.

•

Move truck to a secure non-traffic maintenance area with a level floor.

•

Lockout or tagout truck as described in Lockout Tagout in this section.

•

Turn and hold the key switch to the “start” position for 30 seconds. Voltage lowered below 1V.

•

Turn key switch “OFF” and remove key.

•

Or allow 5 minutes after battery disconnect for capacitors to discharge.

Access 3 Figure 17676

MA-1960-102 01 Rev. 8/08

TSP 6000 Series

Crown 2005 PF15064-3 Rev. 8/08

SAFETY Control of Hazardous Energy Brake The brakes can be released through the use of the Drive/Tow switch (DTS) during a maintenance situation. When using this method to release the brakes, the truck will not have brakes available for stopping. The truck will not have traction control and the power steering system may not work.

WARNING Extreme care must be taken when using Drive/Tow switch to release brakes. The truck will be free-wheeling and the brake pedal in the operator compartment will have no effect on braking. Brakes will only be applied when DTS is moved from Tow to Drive position.

•

Lockout or tagout truck as described in Lockout Tagout in this section.

•

Chock wheels or make sure truck is secured by some means to keep it from free-wheeling.

•

When towing the truck make sure all operators are informed of the trucks lack of braking.

•

Insert brake harness, PC407, to distribution panel.

•

Connect battery. Move switch DTS from the Drive position to the Tow position.

•

Move truck to level area intended for maintenance.

•

Move DTS from the Tow to the Drive position. Disconnect battery.

•

Disconnect brake harness from distribution panel and connect to original connection, CA407.

Crown 2005 PF15064-4 Rev. 8/08

Figure 17675 1

Drive/Tow Switch DTS

Brake Harness PC407

TSP 6000 Series

MA-1960-103 01 Rev. 8/08

SAFETY Control of Hazardous Energy Hydraulic WARNING AVOID HIGH PRESSURE FLUIDS – Escaping fluid under pressure can penetrate the skin causing serious injury. • Relieve pressure before disconnecting hydraulic lines. • Tighten all connections before applying pressure.

•

Lift/Lower System. Open power unit top, rear door and locate the manual lower valve on the right edge towards the top of the power unit.

•

Traverse System. Heed warning about high pressure fluids. Carefully loosen fitting at the sideshift hydraulic motor to relieve pressure.

•

Open the manual lower valve to remove hydraulic pressure.

•

Keep hands and body away from pin holes which eject fluids under high pressure. • Use a piece of cardboard or paper to search for leaks. Do not use your hand. Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately by a specialist who has had experience with this type of injury. When maintenance is to be performed on the hydraulic system, make certain the hydraulic system is not under pressure by:

•

Move truck to a secure non-traffic maintenance area with a level floor.

•

No load on forks.

•

Completely lower load engaging means (mast) or, if required for maintenance, block mast sections at the appropriate height as described in Mast of this section.

•

Lockout or tagout truck as described in Lockout Tagout in this section.

MA-1960-104 01 Rev. 8/08

TSP 6000 Series

Located in Power Unit Figure 17677

Crown 2005 PF15064-5 Rev. 8/08

SAFETY Control of Hazardous Energy Towing Truck

•

Refer to the following guidelines when towing the truck:

Towing by Pulling in Power Unit First Direction WARNING

• • • •

Towed truck must always maintain three contact points with floor and/or towing device. Maximum travel speed while towing truck is 1.6 km/h (1 mph). Do not make sharp turns when lifting and towing this truck. Floor is to be level and flat without trash or debris in towing path.

Tow strap/chains should be long enough to provide safe distance for towed truck to coast to a stop.

Attaching Towing Device To Lift Truck To Be Towed:

•

Use holes in skirt and install eyelets.

Note: Use pull force requirements listed under Towing Device Requirements (see above) to determine specifications of tow strap.

•

Use strap or chain for towing capable of pull force requirements.

Preparing Truck for Towing:

•

Forks should be empty, lowered no more than 305 mm (12.0 in). Load handler and forks should be in home position (make repairs if needed to get forks in this position).

•

Gross vehicle weight should not exceed 8618.3 kg (19000 lb). Refer to data plate for gross vehicle weight; include battery weight if it is in vehicle during towing.

•

Power should be on if steering is not inhibited.

•

Release brakes with brake tow switch. Refer to Brake in Control of Hazardous Energy, Service and Parts Manual page MA-1960-102.

•

Figure 17649

Towing Vehicle Minimum Requirements:

•

Use pull force requirements calculated in Towing Device Requirements to determine traction force. This traction force must be within towing specifications of towing vehicle.

•

Braking force is not applicable; brakes are to be released with brake tow switch.

Operator can be on towed vehicle if steering is not inhibited.

Towing Device Requirements: Note: Excessive acceleration by towing vehicle, or drag caused by towed vehicle (i.e., brake drag, drive unit drag, wheel drag, etc.) will greatly increase requirements to pull or push a vehicle. Note: Drawbar pull tests are required to get reasonable multiplication factor for gross vehicle weight.

•

Holes in Skirt for Eyelets

To calculate pull force requirement, multiply gross vehicle weight by 0.20 (i.e., gross vehicle weight x 0.20) for force needed to pull a vehicle on a flat level surface.

Crown 2005 PF15064-6 Rev. 8/08

Towing Operation Guidelines:

•

Maximum travel speed while towing truck is 1.6 km/h (1 mph).

•

Steering towed vehicle: if steering is operational, a second operator should be on towed vehicle to steer truck. If steering is inhibited, tow vehicle in a straight line out of aisle with no operator on towed truck. Once outside of aisle, make necessary re-

TSP 6000 Series

MA-1960-105 01 Rev. 8/08

SAFETY Control of Hazardous Energy pairs to re-gain steering operation, then follow instructions in previous sentence.

•

Towed truck must always maintain all wheels in contact with floor.

•

Allow sufficient distance for truck to coast to stop at final destination.

•

Using another vehicle, push against skirt of disabled vehicle in forks first direction. Refer to Figure 17650.

Towing by Pushing in Forks First Direction Note: This procedure can be followed if aisle layout/ position of truck in aisle does not allow for pulling truck by power unit skirt. Once truck is outside of aisle, follow previous procedure for pulling truck in power unit first direction.

WARNING

• • • •

Preparing Truck For Towing:

•

Forks should be empty, lowered no more than 305 mm (12.0 in). Load handler and forks should be in home position (make repairs if needed to get forks in this position). Gross vehicle weight should not exceed 8618.3 kg (19000 lb). Refer to data plate for gross vehicle weight; include battery weight if it is in vehicle during towing.

•

Power should be on if steering is not inhibited.

•

Release brakes with brake tow switch. Refer to Brake in Control of Hazardous Energy, Service and Parts Manual page MA-1960-102.

•

Operator can be on towed vehicle if steering is not inhibited.

Pushing Disabled Truck:

MA-1960-106 01 Rev. 8/08

Skirt Figure 17650

Pushing Vehicle Minimum Requirements:

•

Use pull force requirements calculated in Towing Device Requirements to determine traction force. This traction force must be within towing specifications of towing vehicle.

•

Braking force is not applicable; brakes are to be released with brake tow switch.

Towing Operation Guidelines:

•

Maximum travel speed while towing truck is 1.6 km/h (1 mph).

•

Steering towed vehicle: if steering is operational, a second operator should be on towed vehicle to steer truck in a straight line to get it out of aisle. Once outside of aisle, follow previous procedure for towing truck by pulling in power unit first direction. If steering is inhibited, tow vehicle in a straight line out of aisle with no operator on towed truck. Once outside of aisle, make necessary repairs to re-gain steering operation, then follow previous procedure for towing truck by pulling in power unit first direction.

•

Towed truck must always maintain all wheels in contact with floor.

TSP 6000 Series

Crown 2005 PF15064-7 Rev. 8/08

SAFETY Control of Hazardous Energy •

Allow sufficient distance for truck to coast to stop at final destination.

Crown 2005 PF15064-8 Rev. 8/08

TSP 6000 Series

MA-1960-106 01 Rev. 8/08

SAFETY Control of Hazardous Energy Lifting and Blocking

WARNING

•

Move truck to a secure non-traffic maintenance area with a level floor.

•

No load on forks.

•

Lockout or tagout truck as described in Lockout Tagout in this section.

Truck stability decreases dramatically if load wheels are raised more than 13 mm (0.5 in). Attach overhead lifting device to bracket to prevent truck from tipping over when raising the side of the truck. Note:

•

Hydraulic Jack Capacity: 3620 kg (8000 lb) • Crown Part Number: 122599 • Collapsed Height Minimum: 60 mm (2.25 in) • Raised Height Maximum: 400 mm (16 in)

•

Jack Stand Capacity: 4500 kg (10000 lb) • Commercially Available.

Figure 17678 1

Load Wheel

Hardwood Block

Bracket Components TF & TN Mast

Bracket Components TT Mast

109431 Bracket

143043 Bracket

Figure 17679

092832 Pin

060030-054 Flatwasher

060131-006 Flatwasher

060023-006 Bolt

060099-003 Bolt

060000-022 Roll Pin

Wheel chock both load wheels

Set both jack stand heights as required not to exceed 340 mm (13.5 in)

WARNING Do not raise operator platform compartment more than 450 mm (18 in) from floor.

060005-023 Lockwasher

WARNING

Do not raise operator platform compartment more than 450 mm (18 in) from floor.

MA-1960-107 01 Rev. 8/08

Before raising steer wheel end of truck, check that jack does not interfere with guidance sensor.

TSP 6000 Series

Crown 2005 PF15064-9 Rev. 8/08

SAFETY Control of Hazardous Energy Main Mast, Auxiliary Mast and Platform Main Mast - TF & TN Use 100 x 100 mm (4 x 4 in) or bigger hardwood blocks of appropriate length for supporting mast channels. Block both mast rails of each stage to maintain stability. Platform cannot be blocked. After blocks are placed for second stage mast, lower platform to contact stops. 1. Move truck to a secure non-traffic maintenance area with a level floor. 2. Chock wheels of truck (refer to Lifting and Blocking in this section). 3. Connect battery. 4. Raise main mast to obtain desired second stage height and position appropriate length blocks in each mainframe rail. 5. Using a clamp, secure blocks to mainframe.

Note: Use locking tube tool 144009, screws 060115030 and nuts 060059-010 to block mast for chain inspection, or as needed. After locking tube tool is in position, lower main mast to rest on the tool and platform is completely lowered. 2. Chock wheels of truck. Refer to Lifting and blocking in this section. 3. Connect battery. 4. Raise second and third stage mast until blocking hole is visible in first stage mast. 5. Remove screw and nut from one end of locking tube tool and insert tool through first stage mast. Install screw and nut back through locking tube tool to secure in position. 6. Lower mast until the second and third stages are resting on the locking tube tool and the platform is completely lowered. 7. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

6. Lower mast so mast is resting on blocks and platform is against stops. 7. Lockout or tagout truck as described in Lockout Tagout in this section.

Figure 20176

Figure 17664 1

Mainframe

Second Stage

Main Mast - TT 1. Blocking Mast With Locking Tube Tool

Crown 2005 PF15064-10 Rev. 8/08

Locking Tube Tool 144099

Screw 060115-030

Nut 060059-010

Blocking Third Stage Mast Above Second Stage Mast 1. Use two 100 x 75 x 355 mm (4 x 3 x 14 in) hardwood blocks to block third stage mast above second stage mast. 2. Chock wheels of truck. Refer to Lifting and blocking in this section.

TSP 6000 Series

MA-1960-108 01 Rev. 8/08

SAFETY Control of Hazardous Energy 3. Connect battery.

Auxiliary Mast

4. Raise mast until the third stage is a sufficient distance above the second stage and insert the two hardwood blocks into the second stage mast rails.

1. Use 100 x 100 mm (4 x 4 in) or bigger hardwood blocks of appropriate length for supporting mast channels. Block both mast rails to maintain stability.

5. Using a clamp, secure blocks to mast rails. 6. Lower mast so the third stage mast is resting on the two hardwood blocks and the platform is completely lowered. 7. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

2. Move truck to a secure non-traffic maintenance area with a level floor. 3. Chock wheels of truck (refer to Lifting and Blocking in this section). 4. Connect battery. 5. Raise fork carriage to obtain desired height and position appropriate length blocks in both rails. 6. Using a clamp, secure blocks to mast rail. 7. Lower fork carriage so carriage is resting on blocks. 8. Lockout or tagout truck as described in Lockout Tagout in this section.

Figure 20177 1

Hardwood Blocks, 100 x 75 x 355 mm (4 x 3 x 14 in)

Clamp

Third Stage Mast

Second Stage Mast

Figure 8293

Platform - TT The TT platform can be blocked using two 100 x 100 x 405 mm, 4 x 4 x 16 in, hardwood blocks or steel stands, shown. MA-1960-110 01 Rev. 8/08

TSP 6000 Series

Crown 2005 PF15064-11 Rev. 8/08

SAFETY Control of Hazardous Energy 1. Chock wheels of truck. Refer to Lifting and blocking in this section. 2. Connect battery. 3. Raise the platform just enough in free lift to insert steel stands or hardwood blocks into the mast channels. 4. If hardwood blocks are used, secure them in position with a clamp across the two hardwood blocks. 5. Lower platform so it is resting on the steel stands or hardwood blocks. 6. Lockout or tagout truck as described in Battery Lockout/Tagout in this section.

Figure 20178 1

Platform

Main Frame

Jack Stands

Crown 2005 PF15064-12 Rev. 8/08

TSP 6000 Series

MA-1960-110 01 Rev. 8/08

SAFETY Control of Hazardous Energy Height Sensor

4. Separate cover and spacer. Wipe off grease. 5. Carefully pull the arbor from the spring with a needle nose pliers.

WARNING The spring is reverse wound and if not kept restrained, will unwind completely and rewind in the opposite direction. Personal injury is possible if extreme caution is not exercised. It is recommended to wear safety glasses and gloves when removing the spring.

6. Move opening in inside spacer around until spring retainer mounting screws can be accessed. Remove retainer screws. 7. Using a fabricated rod or screwdriver, work spring out of reel 12.7 mm (0.5 in) all the way around.

Tool Fabrication Note: A tool for moving the spring in the reel can be fabricated as shown in Figure 17667.

Figure 17680

Figure 17667 1

4.8 mm (0.1875 in) Diameter Rod

Grind Flat

Screwdriver

Cut and Weld at 90o

Reel Locking Bolt

Spring

Arbor

Reel Cover

8. Securely grip the spring with a vise grip near the end of the spring on the outside diameter. Hold the vise grip with one hand and work the spring from the reel with the fabricated tool.

Spring Removal 1. After the height sensor is removed from the truck, lock the sensor in a vise.

WARNING When the last screw is removed, spring tension will be released through cover rotation of approximately 5 revolutions. 2. Remove four screws from reel cover and allow the spring tension to release through cover rotation.

Figure 17681

3. Pull cover approximately 25.4 mm (1.0 in) from housing and with a screwdriver work the arbor off the square shaft of the cover. MA-1960-111 01 Rev. 8/08

TSP 6000 Series

Crown 2005 PF15064-13 Rev. 8/08

SAFETY Control of Hazardous Energy 1

Spring

Vise Grip

Vice

tainer and reel align. Start screws to hold spring retainer to reel.

9. Carefully wrap numerous cable ties around spring so vise grip can be removed. Discard spring.

Spring Installation 1. When height sensor is ready to have the spring installed, place a vise grip carefully on the reel shaft and secure the vise grip to keep the reel from turning. Place a bolt through reel housing to lock reel.

7. Carefully push spring into reel and allow to expand inside reel. Tighten screws holding spring retainer. 8. Thoroughly soak spring with lubricant (063001-009). 9. Insert arbor into center of spring so when arbor is turned clockwise, flat on arbor pulls spring. 10. Coat both surfaces of end spacer with lubricant (063001-009) and place in reel housing. 11. Insert square shaft of cover into arbor and slide cover against housing. Turn cover clockwise five revolutions. Insert screws and tighten.

Figure 17636 1

Spring

Shipping Rod

2. The new spring is shipped with a rod wrapped partially around the circumference of the spring and is wire tied. Make sure rod is center on the spring and remove the wire ties. 3. Move shipping rod around circumference of spring so end of spring protrudes between ends of rod. 4. Assemble hook of spring retainer in hole of spring. Retainer mounting tab must be on opposite side of spring as the diagonally cut corner at end of spring. 5. Position inside spacer between spring and spring retainer so raised portion of spacer is away from spring. 6. Slide assembly into reel, spring retainer first, and work shipping bar to outer edge of spring. Move assembly around until mounting holes of spring reCrown 2005 PF15064-14 Rev. 8/08

TSP 6000 Series

MA-1960-112 01 Rev. 8/08

SAFETY Control of Hazardous Energy Auxiliary Mast and Platform Lifting Auxiliary Mast The platform weighs approximately 1360 kg (3000 lb) and the load handler weighs approximately 1000 kg (2200 lb). Be sure equipment used to lift and support the load handler and platform is of sufficient capacity to safely handle this load.

7. Using a 3-point hook-up, attach sling, chain, etc. to block and back of overhead guard. Raise platform to the desired height. 8. Block the platform as described in Mast and Platform of this section or remove platform as described in Platform section in this manual.

1. Move truck to a secure non-traffic maintenance area with a level floor. 2. Completely lower main and auxiliary masts. No load on forks. 3. Lockout or tagout truck as described in Lockout Tagout in this section. 4. Chock wheels of truck (refer to Lifting and Blocking in this section). 5. Prepare the auxiliary mast to be removed. Refer to Mast Maintenance section in this manual. 6. Connect hoist to auxiliary mast and raise load handler just enough to transfer the load handler weight from the platform to the hoist. 7. Slowly slide the load handler out of the left side of the platform being careful not to damage the gang hose and cable. 8. Carefully move load handler away from truck.

Figure 17670

Platform 1. Move truck to a secure non-traffic maintenance area with a level floor.

Overhead Guard

Three Point Hookup

Hardwood Block

2. Completely lower main and auxiliary masts. No load on forks. 3. Lockout or tagout truck as described in Lockout Tagout in this section. 4. Chock wheels as described in lifting and blocking in this section. 5. Remove the load handler. Refer to Platform Maintenance section in this manual. 6. Place a 100 x 100 mm (4 x 4 in) hardwood block under the overhead guard, tight against the back of the platform. Be sure the block is at least 305 mm (12.0 in) longer than the overhead guard and is centered. If the truck is equipped with spotlights and overhead fan, disassemble these first from the overhead guard.

MA-1960-113 01 Rev. 8/08

TSP 6000 Series

SAFETY Planned Maintenance - Lubricants

Planned Maintenance - Lubricants To obtain maximum life of any industrial equipment, a well planned maintenance program (PM), performed by qualified technical personnel should be followed. In conjunction with, and an integral part of, any planned maintenance program should be daily operator input. Operator involvement can greatly reduce truck down time, assist in determining planned maintenance (PM) schedules and ultimately save money. For these rea-

sons, Crown recommends a checklist similar to the Operators Daily Checklist shown below. Before performing maintenance to any unit, it should be taken to an area set aside for maintenance or a section where there is adequate space to perform required work. Lockout/Tagout truck as described in Control of Hazardous Energy section of this manual. This is a must to insure the safety of others and to insure that proper maintenance is performed to the unit. If desired, padded packs of this checklist (OF3772) are available through your Crown dealer.

Figure 14990

Crown 2005 PF15083-1 Rev. 11/08

TSP 6000 Series

MA-1960-500 02 Rev. 11/08

SAFETY Planned Maintenance - Lubricants The following is a list of lubricants and maintenance products recommended when doing Planned Maintenance on Crown Lift Trucks. Chart 1 - Lubrication Identification Type of Lubricant A

Part Number

Package Quantity

Gear Lube 75W-90 (Typical)

063002-044

5 Gallon

Grease (Multi-Purpose)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

Grease (Low Temperature)

063002-017 063002-046

14.5 oz Cartridge (40) 14.5 oz Cartridges

Hydraulic Oil

063001-001 063001-015

1 Gallon (6) 1 Gallon

DD1

Hydraulic Oil (Low Temperature)

063001-006

1 Gallon

DDD

Hydraulic Oil (Standard for Blending)

063001-021

1 Gallon

Channel Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

Gear Grease

063002-024 063002-022

14.5 oz Cartridge 35 lb Pail

Grease (Lift Pump Coupling)

063002-039 063002-040

1 lb 1 oz

Brake Fluid - Dot 5

063004-002 063004-003

12 oz 1 Gallon

Grease (Wheel Bearing)

063002-034 063002-045

14.5 oz Cartridge (40) 14.5 oz Cartridges

Metal Assembly Spray

063002-021

11 oz Spray

Silicon Grease (Clear)

063002-020

5.3 oz Tube

Brake & Parts Cleaner

363102-001 363102-012

15 oz Can (12) 15 oz Cans

Brake & Parts Cleaner - Low Volatile Organic Compound

363103-002 363103-012

15 oz Can (12) 15 oz Cans

Non-Flammable Brake & Parts Cleaner

363116-001 363116-012

15 oz Can (12) 15 oz Cans

Penetrating Lubricant

363104-001 363104-012

20 oz Can (12) 20 oz Cans

Premium Formula Multi-Purpose Grease

363108-001 363108-012

11 oz Can (12) 11 oz Cans

B BB1 C D

E F H I J K

O P

Oil (SAE 40)

Rubber & Vinyl Dressing

MA-1960-501 02 Rev. 11/08

TSP 6000 Series

Crown 2005 PF15083-2 Rev. 11/08

SAFETY Planned Maintenance - Lubricants Chart 1 - Lubrication Identification Type of Lubricant Q R S T

Part Number

Package Quantity

White Lithium Grease

363110-001 363109-012

11 oz Can (12) 11 oz Cans

Choke & Carburetor Cleaner

363109-001 363109-012

20 oz Can (12) 20 oz Cans

Contact Cleaner

363106-001 363106-012

10 oz Can (12) 10 oz Cans

Electrical Connector Oxidation & Corrosion Inhibitor

127189-001

30 cc

1 Trucks operated in below freezing temperatures must use Low Temperature Hydraulic Oil & Grease

Chart 2 - Alternate Lubricants & Fluids Type of Lubricant A

Manufacturer/Distributor

Gear Lube 75W-90 (Typical)

Mobilube 1 SHC 75W-901 API GL-4 Dubois EG 0-75 & 901

Mobil Dubois Chemical

Grease (Multi-Purpose)

Union Unoba EP No 2 Retinax A1 LM Grease Mobilgrease XHP 222 Special Unirex EP-2

Union 76 Shell Burmah Castrol Mobil Exxon

Grease (Low Temperature)2

Lubriplate Alvania RA1 Helveum O1

Fiske Bros. Refining Co. Shell Burmah Castrol

Union Unax AW ISO 321 Tellus 321 Hyspin AWS 321 Hydraulic AW-32 Sohio Energol HLP32 Nuto H 32

Union 76 Shell Burmah Castrol Mobil Sohio Exxon

BB C

Product Name

Oil (SAE 40) Hydraulic Oil

Mobil Shell Burmah Castrol Exxon Castrol HDL Inc.

Hydraulic Oil (Low Temperature)2 Mobil Aero HFA Tellus T-151 Hyspin AWH-151 Univis HVI 13 LT Hydraulic Oil

DDD

Hydraulic Oil4

Mobil DTE 24

Mobile

Channel Grease3

Factran #2

Standard Oil

Crown 2005 PF15083-3 Rev. 11/08

TSP 6000 Series

MA-1960-501 02 Rev. 11/08

SAFETY Planned Maintenance - Lubricants Chart 2 - Alternate Lubricants & Fluids Type of Lubricant

Product Name

Manufacturer/Distributor

Gear, Channel & Shaft Grease3

Molykote BR-2 Plus

Dow Corning

Rubber & Vinyl Dressing

Armoral Protectant Clear Guard

Meckesson Corp. Turtle Wax Inc.

Grease (Lift Pump Coupling)

Nyogel 774F-MS

NYE Lubricants

Brake Fluid - DOT5

Q2-1141 Silicon Brake Fluid

Dow Corning

Grease (Wheel Bearing)

Mobilgrease XHP 222 Special Unirex EP-2 Lubriplate # 12421

Mobil Exxon Fiske Bros. Refining Co.

Metal Assembly Spray

Dow Corning

Silicon Grease (Clear)

Dow Corning 111 Compound

Dow Corning

Brake & Parts Cleaner

Crown

Brake & Parts Cleaner - Low Vol- Crown atile Organic Compound

Crown

Non-Flammable Brake & Parts Cleaner

Crown

Penetrating Lubricant

Crown

Premium Formula Multi-Purpose Grease

Crown

White Lithium Grease

Crown

Choke & Carburetor Cleaner

Crown

Contact Cleaner

Crown

Electrical Connector Oxidation & Corrosion Inhibitor

Nye Grease

NYE Lubricants

F H

1 Denotes allowable substitutes, contact factory if unavailable 2 Trucks operated in below freezing temperatures must use Low Temperature Hydraulic Oil & Grease 3 Same as “B” 4 Premium antiwear hydraulic oil used in bleeding with low temperature oil

MA-1960-501 02 Rev. 11/08

TSP 6000 Series

Crown 2005 PF15083-4 Rev. 11/08

LUBRICATION & ADJUSTMENT

Notes:

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Lubrication and Adjustment

Component Accessibility

General Before performing maintenance to the truck, move truck to an area set aside for maintenance or where there is adequate space to perform the required work. This is a must to insure the safety of others and to insure that proper maintenance is performed.

CAUTION Be sure battery connectors are disconnected and all wheels are chocked before proceeding. Lockout/tagout truck as described in the Control of Hazardous Energy section of this manual. To obtain maximum life of any industrial equipment, a well planned maintenance program should be followed. The following information is intended to provide guidelines for proper lubrication intervals, and are according to hours of truck operation and/or a specific number of days or months. These recommended figures should be used as an aid in maintaining safe and efficient truck operation. Some operating conditions will require more frequent checks and lubrication than listed. Applications with much dust or moisture will require modification of the schedule to fit that particular application. Only high grade lubricants and fluids should be used. Sources of these lubricants may be from almost any of the oil companies; those listed are typical and any lubricant with equal specifications may be used. See Inspection and Lubrication for Lube Type designation explanation. On trucks equipped to operate in below freezing temperatures, low temperature hydraulic oil must be used. All screws, washers, nuts, roll pins, retaining rings, etc. need to be coated with a film of rust preventive (078882) to protect against corrosion. Lubrication intervals must be changed to a frequency that will minimize corrosion and wear on moving shafts and parts. On units equipped with Wire Guidance additional inspections should be performed in accordance with the "Wire Guidance Planned Maintenance" check sheet.

Crown 2005 PF15066-1 Rev. 10/08

For regular maintenance, access to various truck components is accomplished by removing covers, panels and/or doors. The following is a general explanation of what cover, panel, etc. must be removed to allow for the most efficient access when performing service and/ or maintenance to components. Refer to the illustrations in this section as an aid in locating parts that require attention. More details are given in following sections on hydraulics, electrical, brakes, etc. The power unit top cover can be opened to allow access to battery connector, battery cell caps, check battery condition. The power unit top rear cover can be opened to allow access to the strobe light and additional electrical components. The left side battery side cover can be removed to service and/or remove battery. The power unit doors can be opened to allow access to the following: drive unit, traction control module (TCM), hydraulic control module (HCM), steering control module (SCM), guidance control module (GCM), traction drive motor, electric brake and related components, steer motor/encoder and related components. Within the operator compartment of the platform are several covers that need to be removed to gain access to switches, encoders, etc. The armrest covers can be removed to allow access to switches, encoders, operator control module (OCM), etc. Removal of the mast side covers gains access to the hydraulic reservoir, manifold block and other hydraulic components. The mast also has several covers, on top and sides, that allow for access to stops, rollers, chain, etc. Refer to the illustrations and charts in this section as a guide for inspection and adjustment that may be necessary. Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment. This information used with a Planned Maintenance Inspection Report for Turret Stockpickers available from your Crown dealer will be very helpful to a good maintenance program.

TSP 6000 Series

M1.0-1960-001 02 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Figure 12736-02

M1.0-1960-002 02 Rev. 10/08

TSP 6000 Series

Crown 2005 PF15066-2 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Chart 1 Lubrication Index

Component

L-1

60 Days

12 Months

250 Hours

2000 Hours

Lube Type

Qty

Multi-Task Handle (Right)

Lube

L-2

Lift Chain

Lube

L-3

Side Gate Pivots

Lube

L-4

Seat Telescoping Tubes

Lube

Chart 2 Inspection And Adjustment Index

Component

60 Days

6 Months

250 Hours

1000 Hours

I-1

Multi-Task Handle (Left & Right)

Check

I-2

Brake Operation

Check

I-3

Brake Switch

Check

I-4

Chain, Chain Anchors & Retainers

Check

I-5

Chain Slack/Break Spring Collars & Switches

Check

I-6

Gate Switches

Check

I-7

Emergency Disconnect

Check

I-8

Indicator Panel Lights & Switches

Check

I-9

Floor Switches

Check

I-10

Seat Switches

Check

I-11

Steering Tiller Control

Check

I-12

Key Switch

Check

I-13

Electrical Connections

Check

I-14

Height Sensor

Check

Crown 2005 PF15066-3 Rev. 10/08

TSP 6000 Series

M1.0-1960-003 02 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Figure 12737-01

M1.0-1960-004 02 Rev. 10/08

TSP 6000 Series

Crown 2005 PF15066-4 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Chart 3 Lubrication Index

Component

Lube Type

Qty

60 Days

90 Days

6 Months

250 Hours

500 Hours

1000 Hours 2000 Hours

L-5

Battery Rollers

As Required

Lube

L-6

Door Hinges

As Required

Lube

L-7

Drive Unit Level

6.2 liters (6.55 qts)

Lube

L-8

Drive Unit Pivot

As Required

Lube

L-9

Hydraulic Filter

Change Change

L-10 Hydraulic Reservoir

47 liters (12.5 gal)

Check

12 Months

Check

L-11 Hydraulic Strainer

Change Check

Change Change

L-12 Steering Gearbox

0.1 liters (0.1 qts)

Lube

L-13 Steering Gears

As Required

Lube

Chart 4 Inspection And Adjustment Index

Component

60 Days

6 Months

250 Hours

1000 Hours

I-15

Battery & Battery Connectors

Check

I-16

Brake Operation

Check

I-17

Contactor Tips

Check

I-18

Drive Tire

Check

I-19

Electrical Connections

Check

I-20

Horn

Check

I-21

Hydraulic Lines, Hoses & Fittings

Check

I-22

Motor - Pump

Check

I-23

Motor - Steering

Check

I-24

Motor Traction

Check

I-25

Power Unit & Mast Bolts - 8 Bolts

Check

I-26

Power Unit Strobe or Flashing Light

Check

I-27

Steering Gears

Check

Crown 2005 PF15066-5 Rev. 10/08

TSP 6000 Series

M1.0-1960-005 02 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Figure 12738-01

M1.0-1960-006 02 Rev. 10/08

TSP 6000 Series

Crown 2005 PF15066-6 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Chart 5 Lubrication 60 Days

12 Months

250 Hours

2000 Hours

Lube Type

Qty

L-14 Load Wheel Axles

As Required

Lube

L-15 Cylinder Yokes

As Required

Lube

L-16 Hose Take-up Cables

As Required

Lube

L-17 Hose Take-up Cam Rollers & Pulleys

As Required

Lube

L-18 Hoses

As Required

Lube

L-19 Lift Chain

As Required

Lube

L-20 Mast Channels

As Required

Lube

L-21 Mast Pulleys (Nylon)

As Required

Lube

L-22 Mast Rollers

As Required

Lube

L-23 Platform & Mast Column Rollers

As Required

Lube

L-24 Rear Cover Hinge

As Required

Lube

L-25 Turret Head Pivot (2 Lube Fittings)

As Required

Lube

Index

Component

Chart 6 Inspection And Adjustment Index

Component

60 Days

6 Months

250 Hours

1000 Hours

I-28

Aisle Guide Wheels

Check

I-29

Aisle Guide Switches

Check

I-30

Load Wheels

Check

I-31

Cable Tension Switches

Check

I-32

Chain Anchors & Retainers

Check

I-33

Column Rollers

Check

I-34

Hose Take Up Cables

Check

I-35

Lift Chain

Check

I-36

Lift Cylinder

Check

I-37

Lift Cylinder Guides, Slides & Stops

Check

I-38

Override Switches

Check

I-39

Shock Absorbers

Check

Crown 2005 PF15066-7 Rev. 10/08

TSP 6000 Series

M1.0-1960-007 02 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

TT Mast

Figure 20857

M1.0-1960-008 02 Rev. 10/08

TSP 6000 Series

Crown 2005 PF15066-8 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Chart 7 Lubrication 60 Days

12 Months

250 Hours

2000 Hours

Lube Type

Qty

L-26 Cylinder Yokes

As Required

Lube

L-27 Hoses

As Required

Lube

L-28 Lift Chain

As Required

Lube

L-29 Mast Channels

As Required

Lube

L-30 Mast Pulleys (Nylon)

As Required

Lube

L-31 Mast Rollers

As Required

Lube

L-32 Platform & Mast Column Rollers

As Required

Lube

L-33 Chain Pulleys

As Required

Lube

Index

Component

Chart 8 Inspection And Adjustment Index

Component

60 Days

6 Months

250 Hours

1000 Hours

I-40

Chain Anchors & Retainers

Check

I-41

Column Rollers

Check

I-42

Lift Chain

Check

I-43

Lift Cylinder

Check

I-44

Lift Cylinder Guides & Stops

Check

I-45

Shock Absorbers

Check

I-46

Chain Slack/Break Switches

Check

I-47

Chain Couplers

Check

Crown 2005 PF15066-9 Rev. 10/08

TSP 6000 Series

M1.0-1960-009 02 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Figure 12739-01

M1.0-1960-010 02 Rev. 10/08

TSP 6000 Series

Crown 2005 PF15066-10 Rev. 10/08

LUBRICATION & ADJUSTMENT Lubrication and Adjustment

Chart 9 Lubrication 60 Days

12 Months

250 Hours

2000 Hours

Lube Type

Qty

L-34 Cylinder Yoke

As Required

Lube

L-35 Fork Slip Ring

As Required

Lube

L-36 Lift Chain

As Required

Lube

L-37 Mast Channels

As Required

Lube

L-38 Mast Pulleys

As Required

Lube

L39

As Required

Lube

L-40 Pivot Chain

As Required

Lube

L-41 Pivot Cylinder Mount

As Required

Lube

L-42 Fork Slides

As Required

Lube

L-43 Traverse Gears

As Required

Lube

L-44 Traverse Pinion (4 Lube Fittings)

As Required

Lube

L-45 Traverse Racks

As Required

Lube

L-46 Hydraulic Motor Chain

As Required

Lube

Index

Component

Mast Column Rollers

Chart 10 Inspection And Adjustment Index

Component

60 Days

6 Months

250 Hours

1000 Hours

I-48

Chain Anchors & Retainers

Check

I-49

Column Rollers & Channels

Check

I-50

Forks

Check

I-51

Hydraulic Lines, Hoses & Fittings

Check

I-52

Lift Chain

Check

I-53

Lift Cylinder

Check

I-54

Lift Limit Switch

Check

I-55

Pivot Cylinder

Check

I-56

Hydraulic Motor

Check

I-57

Traverse Limit Switches

Check

Crown 2005 PF15066-11 Rev. 10/08

TSP 6000 Series

M1.0-1960-011 02 Rev. 10/08

LUBRICATION & ADJUSTMENT Componentry

Componentry Introduction Components listed in this section have been alphabetically categorized to assist the service technician with the following information for each component:

•

Component designator (i.e., ALM1) that will be found on the wiring diagram and parts pages.

•

Description of the component.

•

Location of the component on the truck.

•

Purpose of the component.

•

Technical data of the component.

•

Adjustments required, if applicable.

•

Wiring diagram page(s) on which the component appears (i.e., DIA-1961-003).

•

Parts page on which the component appears. An additional number (in parenthesis) immediately follows the parts page number. The number is the index number of the component (i.e., 04.0-1960-001 (22)).

M1.0-1961-050 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-1 Rev. 12/09

LUBRICATION & ADJUSTMENT Audible Indicators

Audible Indicators ALM1 Status Alarm Location: ACCESS 1 Purpose: draws operator attention to changing truck status Data: controlled through ACCESS 1 Adjustment: N/A Diagrams: DIA-1961-002) DIA-1961-008 Parts Breakdown: 04.8-1960-252 (2)

ALM2 Travel Alarm (Optional) Location: Contactor Panel Purpose: audible warning when traveling forward or reverse Data: 12 to 48 VDC (97 DB) Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-015 Parts Breakdown: 04.1-1961-001 (52)

HN Horn Location: power unit Purpose: provide operator controlled audible warning to the operating area Data: 24 to 48 VDC (105 - 115 DB) Adjustment: N/A Diagrams: DIA-1961-003 DIA-1960-015 Parts Breakdown: 04.0-1961-007 (6)

Crown 2005 PF15321-2 Rev. 12/09

TSP 6000 Series

M1.0-1961-051 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Battery

Battery BATT Location: power unit Purpose: supplies power to truck, components and sensors Data: 48 VDC Adjustment: N/A Diagrams: DIA-1961-004 DIA-1961-024 Parts Breakdown: N/A

M1.0-1961-051 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-3 Rev. 12/09

LUBRICATION & ADJUSTMENT Contactors

Contactors ED1, ED2 Emergency Disconnect Location: contactor panel Purpose: provide ability to turn OFF power circuitry Data: 36 or 48 VDC, 54 Ω coil resistance, continuous duty cycle Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-015 DIA-1961-024 Parts Breakdown: 04.1-1961-001 (14) 04.4-1960-001

K2 Logic Power Location: contactor panel Purpose: provides power to control modules Data: 48 VDC, 325 Ω coil resistance, continuous duty cycle Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-015 Parts Breakdown: 04.1-1961-001 (12)

Crown 2005 PF15321-4 Rev. 12/09

TSP 6000 Series

M1.0-1961-052 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Contactors

Figure 23119

M1.0-1961-052 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-5 Rev. 12/09

LUBRICATION & ADJUSTMENT Encoders

Encoders

ECR4 Traverse Position Encoder

ECR1

Location: load handler top

Steering Command Encoder

Purpose: provide position and speed of traverse drive

Location: left armrest

Data: 64 pulses per revolution

Purpose: provide steering command input to steering module

Adjustment: N/A

Data: 32 pulses per revolution

Diagrams: DIA-1961-002 DIA-1961-023

Adjustments: N/A

Parts Breakdown: 09.1-1960-100 (39)

Diagrams: DIA-1961-002 DIA-1961-020 Parts Breakdown: 04.5-1960-001 (13)

ECR2 Steering Command Encoder Location: left armrest Purpose: provide steering command input to steering module Data: 32 pulses per revolution Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-020 Parts Breakdown: 04.5-1960-001 (13)

ECR3 Auxiliary Mast Height Encoder Location: auxiliary mast Purpose: provide measured height and speed of forks Data: 6.5 counts per mm (166 counts per in) Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-023 Parts Breakdown: 07.7-1960-001 (46)

Crown 2005 PF15321-6 Rev. 12/09

TSP 6000 Series

M1.0-1961-053 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Encoders

Figure 21378

M1.0-1961-054 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-7 Rev. 12/09

LUBRICATION & ADJUSTMENT Encoders ECR5

Adjustment: N/A

Height Sensing Encoder

Diagrams: DIA-1961-003 DIA-1961-018

Location: platform

Parts Breakdown: 02.2-1960-001 (9) 02.2-1960-050 (22)

Purpose: main height sensor Data: 256 pulses per revolution Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-009 Parts Breakdown: 09.0-1960-200 (21)

ECR6 Steering Feedback Encoder Location: power unit Purpose: provide steer wheel movement feedback to steering module Data: 256 pulses per revolution Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-016 Parts Breakdown: 06.0-1960-500 (3)

ECR7 Traction Speed Encoder Location: internal to traction motor Purpose: provide ground speed and direction to control system Data: 64 pulses per revolution Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-016 DIA-1961-022 Parts Breakdown: 03.1-1960-001

ECR8 Pump Motor Encoder Location: internal to pump motor Purpose: provide position and speed of pump motor Data: 64 pulses per revolution

Crown 2005 PF15321-8 Rev. 12/09

TSP 6000 Series

M1.0-1961-055 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Encoders

Figure 21379

M1.0-1961-056 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-9 Rev. 12/09

LUBRICATION & ADJUSTMENT Fuses

Fuses

Purpose: protect drive and tow switch and associated wiring from over current

FU1

Data: 15 A Adjustment: N/A

Control Fuse Location: power unit distribution panel

Diagrams: DIA-1961-003 DIA-1961-006

Purpose: protect control circuitry from over current

Parts Breakdown: 04.3-1960-001 (4)

Data: 15 A

FU5

Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-006

Switched Options Fuse Location: power unit distribution panel

Parts Breakdown: 04.3-1960-001 (4)

Purpose: protect options and associated wiring from over current

FU2

Data: 15 A

Battery Sense Fuse

Adjustment: N/A

Location: power unit distribution panel

Diagrams: DIA-1961-003 DIA-1961-006

Purpose: protect battery sense and associated wiring from over current

Parts Breakdown: 04.3-1960-001 (4)

Data: 15 A Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-006 Parts Breakdown: 04.3-1960-001 (4)

FU3 Un-switched Options Location: power unit distribution panel Purpose: protect options and associated wiring from over current Data: 15 A Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-006 Parts Breakdown: 04.3-1960-001 (4)

FU4 Drive and Tow Switch Fuse Location: power unit distribution panel

Crown 2005 PF15321-10 Rev. 12/09

TSP 6000 Series

M1.0-1961-057 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Fuses

Figure 21380

FU6

Adjustment: N/A

Light and Fan Fuse

Diagrams: DIA-1961-003 DIA-1961-006

Location: power unit distribution panel Purpose: protect light and fan, PS1 and associated wiring from over current Data: 15 A

Parts Breakdown: 04.3-1960-001 (4)

FU8 Power Unit Logic and Flashing Light Fuse

Adjustment: N/A

Location: power unit distribution panel

Diagrams: DIA-1961-003 DIA-1961-006

Purpose: protect power unit logic, flashing light and associated wiring from over current

Parts Breakdown: 04.3-1960-001 (4)

Data: 15 A

FU7

Adjustment: N/A

Platform Logic

Diagrams: DIA-1961-003 DIA-1961-006

Location: power unit distribution panel Purpose: protect platform logic and associated wiring from over current

Parts Breakdown: 04.3-1960-001 (4)

Data: 15 A

M1.0-1961-058 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-11 Rev. 12/09

LUBRICATION & ADJUSTMENT Fuses FU9

FU10

Inner Coil Fuse

Outer Coil Fuse

Location: power unit distribution panel

Purpose: protect brake inner coil and associated wiring from over current

Purpose: protect brake outer coil and associated wiring from over current

Data: 15 A

Adjustment: N/A

Diagrams: DIA-1961-003 DIA-1961-006

Parts Breakdown: 04.3-1960-001 (4)

Figure 21381

Crown 2005 PF15321-12 Rev. 2/09

TSP 6000 Series

M1.0-1961-060 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Fuses FU11

Data: 4 A or ¾ A depending on work light options Adjustment: N/A

ACCESS 3 (TCM) Power Fuse Location: contactor panel Purpose: protect ACCESS 3 and associated wiring from over current Data: 400 A

Diagrams: DIA-1961-002 DIA-1961-004 DIA-1961-005 Parts Breakdown: 04.3-1961-050 (5)

FU15

Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-024

Battery Negative Switched, Un-switched options fuse

Parts Breakdown: 04.1-1961-001 (10)

Location: platform distribution panel Purpose: protect battery negative switched, unswitched options and associated wiring from over current

FU12 ACCESS 2 (HCM) Power Fuse

Data: 15 A

Location: contactor panel Purpose: protect ACCESS 2 and associated wiring from over current Data: 500 A Adjustment: N/A

Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-004 DIA-1961-005 Parts Breakdown: 04.3-1961-050 (6)

Diagrams: DIA-1961-003 DIA-1961-024

FU16

Parts Breakdown: 04.1-1961-001 (11)

Battery Negative Work Light 12 V Power Supply, Fan Fuse

FU13

Location: platform distribution panel

ACCESS 5 (SCM) Power Fuse

Purpose: protect battery negative work dome power supply, fan and associated wiring from over current

Location: contactor panel Purpose: protect ACCESS 5 and associated wiring from over current Data: 50 A

Data: 15 A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-004 DIA-1961-005

Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-024

Parts Breakdown: 04.3-1961-050 (6)

Parts Breakdown: 04.1-1961-001 (7)

FU14 12 V Accessory Fuse (JC) Location: platform distribution panel Purpose: protect 12 V accessories and associated wiring from over current

M1.0-1961-061 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-13 Rev. 12/09

LUBRICATION & ADJUSTMENT Fuses

Figure 21382

Crown 2005 PF15321-14 Rev. 12/09

TSP 6000 Series

M1.0-1961-062 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Fuses FU17

Location: platform 12 V supply in

Battery Negative ACCESS 7 (ACM) Fuse

Purpose: protect work and dome lights and associated wiring from over current

Location: platform distribution panel Purpose: protect battery negative ACCESS 7 and associated wiring from over current

Data: 15 A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-008

Data: 15 A Adjustment: N/A

Parts Breakdown: 04.5-1960-100 (20)

Diagrams: DIA-1961-002 DIA-1961-004 DIA-1961-005

FU21 Work and Dome Lights Fuse

Parts Breakdown: 04.3-1961-050 (6)

Location: platform 12 V supply out

FU18

Purpose: protect work and dome lights and associated wiring from over current

Battery Negative ACCESS 1 (DCM), ACCESS 8 (OCM) Fuse

Data: 15 A

Location: platform distribution panel

Adjustment: N/A

Purpose: protect battery negative ACCESS 1, ACCESS 8 and associated wiring from over current

Diagrams: DIA-1961-002 DIA-1961-008

Data: 15 A

Parts Breakdown: 04.5-1960-100 (20)

Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-004 DIA-1961-005 Parts Breakdown: 04.3-1961-050 (6)

FU19 Battery Negative ACCESS 4 (VCM) Fuse Location: platform distribution panel Purpose: protect battery negative ACCESS 4 and associated wiring from over current Data: 15 A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-004 DIA-1961-005 Parts Breakdown: 04.3-1961-050 (6)

FU20 Work and Dome Lights Fuse

M1.0-1961-063 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-15 Rev. 12/09

LUBRICATION & ADJUSTMENT Fuses

Power Supply

Figure 21383

Crown 2005 PF15321-16 Rev. 12/09

TSP 6000 Series

M1.0-1961-064 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Lights

Lights

Diagrams: DIA-1961-007 Parts Breakdown: 04.0-1961-200 (56)

LGT1

LGT5

Strobe or Flashing Light (Optional)

Right Work Light

Location: power unit

Location: overhead guard

Purpose: visual warning of lift truck presence

Purpose: provide work area light outside operator compartment

Data: N/A Adjustment: N/A

Data: 12 V

Diagrams: DIA-1961-003 DIA-1961-015

Adjustment: limited adjustment of beam direction Diagrams: DIA-1961-007

Parts Breakdown: 04.0-1961-007 (35)

Parts Breakdown: 04.0-1961-200 (56)

LGT2 Left Dome Light Location: overhead guard Purpose: provide light for operator compartment Data: 12 V Adjustment: N/A Diagrams: DIA-1961-007 Parts Breakdown: 04.0-1961-200 (40)

LGT3 Right Dome Light Location: overhead guard Purpose: provide light for operator compartment Data: 12 V Adjustment: N/A Diagrams: DIA-1961-007 Parts Breakdown: 04.0-1961-200 (40)

LGT4 Left Work Light Location: overhead guard Purpose: provide work area light outside operator compartment Data: 12 V Adjustment: limited adjustment of beam direction M1.0-1961-065 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-17 Rev. 12/09

LUBRICATION & ADJUSTMENT Lights

Figure 21384

Crown 2005 PF15321-18 Rev. 12/09

TSP 6000 Series

M1.0-1961-066 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Lights LGT 6 Left Work Light (Optional) Location: overhead guard Purpose: provide work area light outside operator compartment Data: 12 V Adjustment: limited adjustment of beam direction Diagrams: DIA-1961-007 Parts Breakdown: 04.0-1961-200 (38)

LGT 7 Right Work Light (Optional) Location: overhead guard Purpose: provide work area light outside operator compartment Data: 12 V Adjustment: limited adjustment of beam direction Diagrams: DIA-1961-007 Parts Breakdown: 04.0-1960-200 (38)

LGT8 Strobe or Flashing Light (Optional) Location: under platform Purpose: visual warning of lift truck presence Data: N/A Adjustment: N/A Diagrams: DIA-1961-012 Parts Breakdown: 04.0-1961-200 (4)

LGT9 Strobe or Flashing Light (Optional) Location: under platform Purpose: visual warning of lift truck presence Data: N/A Adjustment: N/A Diagrams: DIA-1961-012 Parts Breakdown: 04.0-1961-200 (4) M1.0-1961-067 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-19 Rev. 12/09

LUBRICATION & ADJUSTMENT Lights

Figure 21385

Crown 2005 PF15321-20 Rev. 12/09

TSP 6000 Series

M1.0-1961-068 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Miscellaneous

Miscellaneous

Data: with high performance hydraulic package Adjustment: N/A

BRK

Diagrams: DIA-1961-003 DIA-1961-017

Brake

Parts Breakdown: 04.0-1961-007(104)

Location: traction motor Purpose: provide braking force to traction motor to stop truck and prevent movement of parked vehicle Data: N/A Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-016 Parts Breakdown: 04.0-1961-007 (87) 05.3-1960-001

FSB1 Feedback Splitter Location: traction motor Purpose: traction motor feedback splitter Data: N/A Adjustment: N/A

EAC Distribution Panel

Diagrams: DIA-1961-003 DIA-1961-016 DIA-1961-022

Location: mainframe bumper

Parts Breakdown: 04.0-1961-007 (96)

Purpose: provide central connection point for end aisle control sensors

FSB2

Data: N/A

Feedback Splitter (Optional)

Adjustment: N/A

Location: PDS mounting bracket in power unit

Diagrams: DIA-1961-003 DIA-1961-021

Purpose: PDS feedback splitter

Parts Breakdown: 10.4-1960-150 (15) 10.4-1960-250 (15)

Data: N/A Adjustment: N/A

FAN1

Diagrams: DIA-1961-003 DIA-1961-016 DIA-1961-022

Operator Fan Right Side (Optional)

Parts Breakdown: 04.0-1961-007 (27)

Location: overhead guard Purpose: operator comfort Data: 48 V Adjustment: N/A Diagrams: DIA-1961-007 Parts Breakdown: 04.0-1961-200 04.9-1961-050 (10)

FAN3 Cooling Fan for ACCESS 2 (HCM) (Optional) Location: power unit Purpose: cooling for ACCESS 2 module M1.0-1961-069 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-21 Rev. 12/09

LUBRICATION & ADJUSTMENT Miscellaneous

Fan Located in Power Unit

EAC Distribution Panel

Figure 23120

Crown 2005 PF15321-22 Rev. 12/09

TSP 6000 Series

M1.0-1961-070 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Miscellaneous JC

Diagrams: DIA-1961-012 Parts Breakdown: 04.0-1961-200 (6)

12 V Receptacle Location: console

HYDRAULIC RESERVOIR

Purpose: 12 V receptacle

Location: mainframe

Data: N/A

Purpose: hydraulic oil storage

Adjustment: N/A

Data: 47.3 liters (12.5 gallons)

Diagrams: DIA-1961-002 DIA-1961-008

Adjustment: N/A Diagrams: HYD-1960-001

Parts Breakdown: 04.5-1960-100 (13)

Parts Breakdown: 02.0-1960-001 (11)

P1 Hydraulic Pump Location: mainframe Purpose: provide hydraulic fluid flow for hydraulic functions Data: 18.9 displacement, 22 cc displacement for high performance Adjustment: N/A Diagrams: HYD-1960-001 Parts Breakdown: 02.0-1960-001 (24) 02.1-1960-001

PS1 Power Supply Location: console Purpose: provide 12 V for fan and lights package Data: 36 V or 48 V in, 12.8 V out Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-008 Parts Breakdown: 04.5-1960-100 (20)

PS2 Power Supply (Optional) Location: platform Purpose: provide power for platform strobe light Data: N/A Adjustment: N/A M1.0-1961-071 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-23 Rev. 12/09

LUBRICATION & ADJUSTMENT Miscellaneous

Reservoir

Figure 21387

Crown 2005 PF15321-24 Rev. 12/09

TSP 6000 Series

M1.0-1961-072 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Modules

Modules

Location: platform Purpose: control vehicle operation

ACCESS 1

Data: N/A

Display Control Module

Adjustment: N/A

Location: left post of platform

Diagrams: DIA-1961-002 DIA-1961-010

Purpose: display for operator information (including direction, speed and position), service mode messages and indicators

Parts Breakdown: 04.8-1960-252 (7)

Data: 22 V to 55 V input Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-008 Parts Breakdown: 04.8-1960-252 (2)

ACCESS 2 Hydraulic Control Module Location: power unit right rear Purpose: controls hydraulic motor, hydraulic solenoids and reads CTS and HCS Data: 48 VDC to 80 VDC input Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-017 DIA-1961-024 Parts Breakdown: 04.0-1961-007 (99)

ACCESS 3 Traction Control Module Location: power unit left rear Purpose: control traction operation Data: 48 VDC to 80 VDC input Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-013 DIA-1961-024 Parts Breakdown: 04.0-1961-007 (40)

ACCESS 4 Vehicle Control Module M1.0-1961-073 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-25 Rev. 12/09

LUBRICATION & ADJUSTMENT Modules

Figure 21388

Crown 2005 PF15321-26 Rev. 12/09

TSP 6000 Series

M1.0-1961-074 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Modules ACCESS 5

ACCESS 8

Steering Control Module

Operator Control Module

Location: power unit left rear

Location: right armrest

Purpose: control steering operation

Purpose: provide information from operator controlled inputs

Data: N/A

Adjustment: N/A

Diagrams: DIA-1961-003 DIA-1961-014 DIA-1961-024

Diagrams: DIA1961-002 DIA-1961-019

Parts Breakdown: 04.0-1961-007 (48)

Parts Breakdown: 04.6-1960-001 (56)

ACCESS 6 Guidance Control Module (Optional) Location: power unit right rear Purpose: controls automatic guidance system and EAC (wire guidance) Data: N/A Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-021 Parts Breakdown: 04.0-1961-007 (14)

ACCESS 7 Accessory Control Module Location: load handler Purpose: controls load handler hydraulic valves and reads POT5, EAC4, EAC3, FHSL, FHSR, HGTRS2, TVRS switches and LS Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-023 Parts Breakdown: 09.1-1960-150 (16)

M1.0-1961-075 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-27 Rev. 12/09

LUBRICATION & ADJUSTMENT Modules

Figure 21389

Crown 2005 PF15321-28 Rev. 12/09

TSP 6000 Series

M1.0-1961-076 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Motors

Motors M1 AC Traction Motor Location: drive unit Purpose: provide driving force for traction Data: 7.3 KW output Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-016 DIA-1961-024 Parts Breakdown: 03.1-1960-001

M2 AC Hydraulic Pump Motor Location: mainframe Purpose: provide driving force for hydraulic pump supplying hydraulic oil flow for lift, traverse and pivot Data: 16.2 KW output Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-018 DIA-1961-024 Parts Breakdown: 02.2-1960-001 02.2-1960-050

M3 Steering Motor Location: drive unit Purpose: provide driving force for steering Data: 48 V Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-024 Parts Breakdown: 06.2-1960-001

M1.0-1961-077 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-29 Rev. 12/09

LUBRICATION & ADJUSTMENT Motors

Figure 21390

Crown 2005 PF15321-30 Rev. 12/09

TSP 6000 Series

M1.0-1961-078 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Potentiometers

Potentiometers

Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-019

POT1

Parts Breakdown: 04.6-1960-001 (2)

Traction Command Location: right armrest

POT5

Purpose: provide traction input to ACCESS 3

Pivot Position

Data: N/A

Location: load handler

Adjustment: N/A

Purpose: provide pivot position input to ACCESS 7

Diagrams: DIA-1961-002 DIA-1961-019

Data: N/A Adjustment: N/A

Parts Breakdown: 04.6-1960-001 (14)

Diagrams: DIA-1961-002 DIA-1961-023

POT2

Parts Breakdown: 09.1-1960-150 (2)

Main Hoist Raise and Lower Location: right armrest Purpose: provide raise and lower input to ACCESS 8 Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-019 Parts Breakdown: 04.6-1960-001 (15)

POT3 Auxiliary Hoist Raise and Lower Location: left armrest Purpose: provide raise and lower input to ACCESS 8 Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-020 Parts Breakdown: 04.5-1960-001 (6)

POT4 Traverse Command Location: right armrest Purpose: provide traverse input to ACCESS 8 Data: N/A

M1.0-1961-079 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-31 Rev. 12/09

LUBRICATION & ADJUSTMENT Potentiometers

Figure 21391

Crown 2005 PF15321-32 Rev. 12/09

TSP 6000 Series

M1.0-1961-080 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Relays

Relays

Purpose: CAN balancing resistor Data: N/A

Adjustment: N/A

Power Up Relay

Diagrams: DIA-1961-023

Location: platform distribution panel

Parts Breakdown: N/A

Purpose: provides control circuitry power Data: 48 V Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-004 DIA-1961-005 Parts Breakdown: 04.3-1961-050 (7)

Resistors RES1

RES4 Travel Alarm Resistor Location: contactor panel Purpose: travel alarm Data: N/A Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-015 Parts Breakdown: 04.1-1961-001 (51)

Drive Tow Resistor

RES5

Location: contactor panel

Override Switch Resistor

Purpose: dropping resistor for drive tow

Location: contactor panel

Data: 10 Ω

Purpose: override switch

Adjustment: N/A

Data: 8 Ω

Diagrams: DIA-1961-003 DIA-1961-006

Adjustment: N/A

Parts Breakdown: 04.1-1961-001 (21)

RES2

Diagrams: DIA-1961-003 DIA-1961-006 Parts Breakdown: 04.1-1961-001 (18)

Drive Tow Resistor Location: contactor panel Purpose: dropping resistor for drive tow Data: 10 Ω Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-006 Parts Breakdown: 04.1-1961-001 (19)

RES3 CAN Balancing Resistor Location: load handler (inside wire harness) M1.0-1961-081 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-33 Rev. 12/09

LUBRICATION & ADJUSTMENT Relays

(inside wire harness)

Figure 21392

Crown 2005 PF15321-34 Rev. 12/09

TSP 6000 Series

M1.0-1961-082 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Sensors

Sensors

Location: mainframe bumper Purpose: to signal operator of approaching end or intersection of aisle

CS1

Data: 12 V

Current Sensor

Adjustment: N/A

Location: contactor panel Purpose: monitor current through BDI to determine battery status Data: N/A

Diagrams: DIA-1961-003 DIA-1961-021 Parts Breakdown: 10.4-1960-150 (21) 10.4-1960-250 (21)

Adjustment: N/A

EACB2

Diagrams: DIA-1961-003 DIA-1961-015

End Aisle Control B2

Parts Breakdown: 04.1-1961-001 (37)

Location: mainframe bumper

EACA1

Purpose: to signal operator of approaching end or intersection of aisle

End Aisle Control A1

Data: 12 V

Location: mainframe bumper

Adjustment: N/A

Purpose: to signal operator of approaching end or intersection of aisle

Diagrams: DIA-1961-003 DIA-1961-021

Data: 12 V

Parts Breakdown: 10.4-1960-150 (21) 10.4-1960-250 (21)

Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-021 Parts Breakdown: 10.4-1960-150 (21) 10.4-1960-250 (21)

EACA2 End Aisle Control A2 Location: mainframe bumper Purpose: to signal operator of approaching end or intersection of aisle Data: 12 V Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-021 (A-3) Parts Breakdown: 10.4-1960-150 (21) 10.4-1960-250 (21)

EACB1 End Aisle Control B1 M1.0-1961-083 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-35 Rev. 12/09

LUBRICATION & ADJUSTMENT Sensors

Figure 21393

Crown 2005 PF15321-36 Rev. 12/09

TSP 6000 Series

M1.0-1961-084 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Sensors GS1

Adjustment: N/A Diagrams: DIA-1961-022

Steer Wheel Guidance Sensor Bar

Parts Breakdown: 04.0-1961-001

Location: power unit Purpose: sense signal strength from guide wire embedded in floor

TS1

Data: N/A

Temperature Sensor

Adjustment: N/A

Location: traction motor M1

Diagrams: DIA-1961-003 DIA-1961-021

Purpose: monitor motor temperature Data: N/A

Parts Breakdown: 06.7-1960-001 (8)

Adjustment: N/A

GS2

Diagrams: DIA-1961-003 DIA-1961-016

Load Wheel Sensor Bar

Parts Breakdown: 03.1-1960-001

Location: mainframe

TS2

Purpose: sense signal strength from guide wire embedded in floor

Temperature Sensor

Data: N/A

Location: hydraulic motor M2

Adjustment: N/A

Purpose: monitor motor temperature

Diagrams: DIA-1961-003 DIA-1961-021

Data: N/A Adjustment: N/A

Parts Breakdown: 06.7-1960-001 (1)

Diagrams: DIA-1961-003 DIA-1961-018

Parts Breakdown: 02.2-1960-001 02.2-1960-050

Load Sense Location: load handler Purpose: provide approximate weight measurement on forks for data capacity monitor Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-023 Parts Breakdown: 02.0-1960-200 (32)

PDS Pedestrian Detection Sensor Location: power unit Purpose: detect pedestrians and sound alarm Data: N/A

M1.0-1961-085 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-37 Rev. 12/09

LUBRICATION & ADJUSTMENT Sensors

(Supplied by Vendor)

Figure 21394

Crown 2005 PF15321-38 Rev. 12/09

TSP 6000 Series

M1.0-1961-086 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Solenoid Valves

Solenoid Valves

Adjustment: N/A

EML

Diagrams: HYD-1960-001 DIA-1961-002 DIA-1961-023

Seat Locking Solenoid

Parts Breakdown: 02.4-1960-054 (6)

Location: seat base Purpose: locks operator seat in position

PVAR

Data: N/A

Proportional Auxiliary Raise Valve

Adjustment: N/A

Location: load handler manifold

Diagrams: DIA-1961-002 DIA-1961-011

Purpose: provide proportional flow control of auxiliary raise functions

Parts Breakdown: 09.0-1960-150 (103)

Data: fits C10-2 cavity Adjustment: N/A

MVL

Diagrams: HYD-1960-001 DIA-1961-002 DIA-1961-023

Manual Valve Lowering Location: power unit in mainframe manifold Purpose: provides means to lower platform without truck powered up

Parts Breakdown: 02.4-1960-054 (6)

Data: N/A Adjustment: N/A Diagrams: HYD-1960-001 Parts Breakdown: 02.4-1960-001 (5)

PCML Main Lower Proportional Valve Location: mainframe manifold Purpose: provide proportional flow control during lowering Data: N/A Adjustment: N/A Diagrams: HYD-1960-001 Parts Breakdown: 02.4-1960-001 (28)

PVAL Proportional Auxiliary Lowering Valve Location: load handler manifold Purpose: provide proportional flow control of auxiliary lowering functions Data: fits C10-2 cavity M1.0-1961-087 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-39 Rev. 12/09

LUBRICATION & ADJUSTMENT Solenoid Valves

Figure 21395

Crown 2005 PF15321-40 Rev. 12/09

TSP 6000 Series

M1.0-1961-088 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Solenoid Valves PVF1 Proportional Fork Extend Valve Location: load handler manifold Purpose: provide proportional flow control of fork extend Data: fits C08-4 cavity Adjustment: N/A Diagrams: HYD-1960-001 DIA-1961-002 DIA-1961-023 Parts Breakdown: 02.4-1960-054 (30)

PVF2 Proportional Fork Retract Valve Location: load handler manifold Purpose: provide proportional flow control of fork retract Data: fits C08-4 cavity Adjustment: N/A Diagrams: HYD-1960-001 DIA-1961-002 DIA-1961-023 Parts Breakdown: 02.4-1960-054 (30)

PVLH Proportional Relief Valve Location: load handler manifold Purpose: provide proportional control of auxiliary relief pressure setting Data: fits C10-2 cavity Adjustment: N/A Diagrams: HYD-1960-001 DIA-1961-002 DIA-1961-023 Parts Breakdown: 02.4-1960-054 (7)

M1.0-1961-089 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-41 Rev. 12/09

LUBRICATION & ADJUSTMENT Solenoid Valves

Figure 23122

Crown 2005 PF15321-42 Rev. 12/09

TSP 6000 Series

M1.0-1961-090 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Solenoid Valves PVML

Purpose: provide proportional flow to the pivot cylinder per operator request, CW or CCW

Main Lower Proportional Valve

Data: fits C08-5 cavity

Location: mainframe manifold Purpose: provide proportional flow to lower main lift cylinders

Adjustment: N/A

Data: fits C12-2 cavity

Diagrams: HYD-1960-001 DIA-1961-002 DIA-1960-023

Adjustment: N/A

Parts Breakdown: 02.4-1960-054 (28)

Diagrams: HYD-1960-001 DIA-1961-003 DIA-1961-018

PVT1 Proportional Traverse Valve

Parts Breakdown: 02.4-1960-001 (28)

Location: load handler manifold

PVMR

Purpose: provide proportional flow to the traverse hydraulic motor per operators request

Main Raise Proportional Valve

Data: fits C08-5 cavity

Location: mainframe manifold Purpose: provide proportional flow to raise main lift cylinders

Adjustment: N/A

Data: fits C12-2 cavity

Diagrams: HYD-1960-001 DIA-1961-002 DIA-1961-023

Adjustment: N/A

Parts Breakdown: 02.4-1960-054 (29)

Diagrams: HYD-1960-001 DIA-1961-003 DIA-1961-018

PVT2 Proportional Traverse Valve

Parts Breakdown: 02.4-1960-001 (29)

Location: load handler manifold

PVP1

Purpose: provide proportional flow to the traverse hydraulic motor per operators request

Proportional Pivot Valve

Data: fits C08-5 cavity

Location: load handler manifold Purpose: provide proportional flow to the pivot cylinder per operator request, CW or CCW

Adjustment: N/A

Data: fits C08-5 cavity

Diagrams: HYD-1960-001 DIA-1961-002 DIA-1961-023

Adjustment: N/A

Parts Breakdown: 02.4-1960-054 (29)

Diagrams: HYD-1960-001 DIA-1961-002 DIA-1960-023 Parts Breakdown: 02.4-1960-054 (28)

PVP2 Proportional Pivot Valve Location: load handler manifold

M1.0-1961-091 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-43 Rev. 12/09

LUBRICATION & ADJUSTMENT Solenoid Valves

Figure 23123

Crown 2005 PF15321-44 Rev. 12/09

TSP 6000 Series

M1.0-1961-092 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Solenoid Valves SP1 Auxiliary Proportional Valve Location: mainframe manifold Purpose: directs hydraulic oil for all auxiliary load handler functions Data: fits C10-2 cavity Adjustment: N/A Diagrams: HYD-1960-001 DIA-1961-003 DIA-1961-018 Parts Breakdown: 02.4-1960-001 (3)

SVAL Velocity Fuse Location: auxiliary cylinder base Purpose: to stop lift cylinder from lowering if speed exceeds 36.5 m/min (120 ft/min) Data: fits C10-2 cavity Adjustment: N/A Diagrams: HYD-1960-001 DIA1961-002 DIA-1961-023 Parts Breakdown: 02.0-1960-200 (28)

SVML Main Lower Solenoid Valve Location: mainframe manifold Purpose: prevents drift Data: fits C12-2 cavity Adjustment: N/A Diagrams: HYD-1960-001 DIA-1961-003 DIA-1961-018 Parts Breakdown: 02.4-1960-001 (27)

M1.0-1961-093 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-45 Rev. 12/09

LUBRICATION & ADJUSTMENT Solenoid Valves

Figure 23124

Crown 2005 PF15321-46 Rev. 12/09

TSP 6000 Series

M1.0-1961-094 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Suppressor Blocks

Suppressor Blocks SB11 Key Switch Suppressor Block Location: platform distribution panel Purpose: key switch suppression Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-004 Parts Breakdown: 04.0-1960-200 04.3-1960-050 (10)

SB31 Operator Fan Suppressor Location: platform Purpose: suppress electrical noise Data: N/A Adjustment: N/A Diagrams: DIA-1961-007 Parts Breakdown: 4.9-1961-050 (13)

SB41 ACCESS 2 Cooling Fan Suppressor (Optional) Location: power unit, ACCESS 2 HCM fan bracket Purpose: suppress electrical noise Data: N/A Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-017 Parts Breakdown: 04.0-1960-007 (105)

M1.0-1961-095 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-47 Rev. 12/09

LUBRICATION & ADJUSTMENT Suppressor Blocks

Figure 23125

Crown 2005 PF15321-48 Rev. 12/09

TSP 6000 Series

M1.0-1961-096 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Switches

Diagrams: DIA-1961-002 DIA-1961-012

APS

Parts Breakdown: 09.2-1960-001 (5)

Auto Pivot Switch

BRS3

Location: left armrest

Brake Switch, Left Brake Pedal

Purpose: auto pivot switch

Location: platform below floorboard

Data: normally open

Purpose: allows operator to apply or release brakes

Adjustment: N/A

Data: normally closed

Diagrams: DIA-1961-020

Adjustment: N/A

Parts Breakdown: 04.5-1960-001 (7)

Diagrams: DIA-1961-002 DIA-1961-012

BRES

Parts Breakdown: 09.2-1960-001 (5)

Battery Restraint Switch (Optional) Location: power unit left side

BRS4

Purpose: battery restraint switch

Brake Switch, Left Brake Pedal

Data: normally closed

Location: platform below floorboard

Adjustment: N/A

Purpose: allows operator to apply or release brakes

Diagrams: DIA-1961-003 DIA-1961-014

Data: normally closed Adjustment: N/A

Parts Breakdown: 04.0-1961-001 (51)

Diagrams: DIA-1961-002 DIA-1961-012

BRS1

Parts Breakdown: 09.2-1960-001 (5)

Brake Switch, Right Brake Pedal Location: platform below floorboard Purpose: allows operator to apply or release brakes Data: normally closed Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-012 Parts Breakdown: 09.2-1960-001 (5)

BRS2 Brake Switch, Right Brake Pedal Location: platform below floorboard Purpose: allows operator to apply or release brakes Data: normally closed Adjustment: N/A M1.0-1961-097 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-49 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Located on Power Unit Left Side

Figure 21399

Crown 2005 PF15321-50 Rev. 12/09

TSP 6000 Series

M1.0-1961-098 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches CHS1

Purpose: prohibits raising or lowering if mast chains should break

Chain Slack Switch

Data: Normally Closed

Location: base of platform Purpose: prohibits lowering if mast chains become slack Data: normally closed

Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-009

Adjustment: N/A

Parts Breakdown: 07.6-1960-001 (15) 07.6-1960-100 (15)

Diagrams: DIA-1961-002 DIA-1961-009

CHS5

Parts Breakdown: 07.6-1960-001 (10) 07.6-1960-100 (15)

Chain Slack Switch

CHS2

Purpose: prohibits lowering if mast chains become slack

Location: top of mainframe

Chain Slack Switch

Data: normally closed

Location: base of platform Purpose: prohibits lowering if mast chains become slack Data: normally closed

Diagrams: DIA-1961-003 DIA-1961-018 Parts Breakdown: 07.6-1960-150 (6)

Adjustment: N/A

CHS6

Diagrams: DIA-1961-002 DIA-1961-009

Chain Slack Switch

Parts Breakdown: 07.6-1960-001 (11) 07.6-1960-100 (15)

Location: top of mainframe Purpose: prohibits lowering if mast chains become slack

CHS3

Data: normally closed

Chain Break Switch

Adjustment: N/A

Location: base of platform Purpose: prohibits raising or lowering if mast chains should break Data: normally closed

Adjustment: N/A

Diagrams: DIA-1961-003 DIA-1961-018 Parts Breakdown: 07.6-1960-150 (6)

Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-009 Parts Breakdown: 07.6-1960-001 (14) 07.6-1960-100 (15)

CHS4 Chain Break Switch Location: base of platform

M1.0-1961-099 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-51 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Figure 21400

Crown 2005 PF15321-52 Rev. 12/09

TSP 6000 Series

M1.0-1961-100 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches CHS7

Diagrams: DIA-1961-003 DIA-1961-006

Chain Break Switch

Parts Breakdown: 04.3-1960-001 (3)

Location: top of mainframe Purpose: prohibits raising or lowering if mast chains should break Data: normally closed

Purpose: resets the emergency disconnect contactor, removing power from power and control circuitry

Diagrams: DIA-1961-003 DIA-1961-018

Data: normally closed

Parts Breakdown: 07.6-1960-150 (6)

Adjustment: N/A

CHS8

Diagrams: DIA-1961-002 DIA-1961-019

Chain Break Switch

Parts Breakdown: 04.6-1960-001 (27)

Location: top of mainframe Purpose: prohibits raising or lowering if mast chains should break Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-018 Parts Breakdown: 07.6-1960-150 (6)

CTS (TF Mast Only) Cable Tension Switch Location: top of mainframe

Emergency Disconnect Switch Location: right armrest

Adjustment: N/A

Data: normally closed

EDS

EMS1 Emergency Switch (Traverse) Location: platform Purpose: during an electrical malfunction allows operation of traverse functions Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-004 Parts Breakdown: 04.0-1961-200 (1)

Purpose: monitors hose take up cable Data: normally closed Adjustment: N/A Diagrams: DIA-1961-003 DIA-1961-018 Parts Breakdown: 07.5-1960-200 (35)

DTS Drive Tow Switch Location: power unit distribution panel Purpose: release brake for towing Data: normally open Adjustment: N/A M1.0-1961-101 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-53 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Distribution Panel

Figure 21401

Crown 2005 PF15321-54 Rev. 12/09

TSP 6000 Series

M1.0-1961-102 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches EMS2

Adjustment: N/A Diagrams: DIA-1961-008

Traverse Override

Parts Breakdown: 04.5-1960-100 (14)

Location: power unit right side Purpose: during an electrical malfunction allows operation of traverse functions

FPS1

Data: normally open

Foot Presence Switch

Adjustment: N/A

Location: platform floorboard

Diagrams: DIA-1961-003 DIA-1961-017

Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Parts Breakdown: 04.0-1961-001 (12)

Data: normally open

FHSL

Adjustment: N/A

Fork Home Switch

Diagrams: DIA-1961-002 DIA-1961-012

Location: fork assembly Purpose: lock out pivot function when forks are out of home position Data: normally closed

Parts Breakdown: 09.2-1960-050 (3)

FPS2 Foot Presence Switch

Adjustment: N/A

Location: platform floorboard

Diagrams: DIA-1961-002 DIA-1961-023

Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Parts Breakdown: 07.9-1960-003 (10)

Data: normally open

FHSR

Adjustment: N/A

Fork Home Switch

Diagrams: DIA-1961-002 DIA-1961-012

Location: fork assembly Purpose: lock out pivot function when forks are out of home position

Parts Breakdown: 09.2-1960-050 (3)

Data: normally closed Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-023 Parts Breakdown: 07.9-1960-003 (10)

FNS Operator Fan Switch Location: platform console Purpose: allows operator to turn fan ON or OFF Data: N/A

M1.0-1961-103 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-55 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Figure 21402

Crown 2005 PF15321-56 Rev. 12/09

TSP 6000 Series

M1.0-1961-104 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches FPS3 Foot Presence Switch

Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Location: platform floorboard

Data: normally open

Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Adjustment: N/A

Data: normally open

Diagrams: DIA-1961-002 DIA-1961-012 Parts Breakdown: 09.2-1960-050 (3)

Adjustment: N/A

FPS7

Diagrams: DIA-1961-002 DIA-1961-012

Foot Presence Switch

Parts Breakdown: 09.2-1960-050 (3)

Location: platform floorboard

FPS4 Foot Presence Switch

Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Location: platform floorboard

Data: normally open

Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Adjustment: N/A

Data: normally open

Diagrams: DIA-1961-002 DIA-1961-012 Parts Breakdown: 09.2-1960-050 (3)

Adjustment: N/A

FPS8

Diagrams: DIA-1961-002 DIA-1961-012

Foot Presence Switch

Parts Breakdown: 09.2-1960-050 (3)

Location: platform floorboard

FPS5 Foot Presence Switch

Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Location: platform floorboard

Data: normally open

Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Adjustment: N/A

Data: normally open Adjustment: N/A

Diagrams: DIA-1961-002 DIA-1961-012 Parts Breakdown: 09.2-1960-050 (3)

FPS6 Foot Presence Switch Location: platform floorboard

M1.0-1961-105 02 Rev. 12/09

TSP 6000 Series

Crown 2005 PF15321-57 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Figure 21403

Crown 2005 PF15321-58 Rev. 12/09

TSP 6000 Series

M1.0-1961-106 02 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches FPS9

Data: normally open Adjustment: N/A

Foot Presence Switch Location: platform floorboard Purpose: sense operator presence to enable traction and hydraulic functions and to apply brake when foot is removed while in stand up mode

Diagrams: DIA-1961-002 DIA-1961-009 Parts Breakdown: 09.1-1960-001 (29)

Data: normally open

GUS

Adjustment: N/A

Guidance Select Switch (Optional)

Diagrams: DIA-1961-002 DIA-1961-012

Location: right armrest Purpose: allows operator to select manual or automatic steering

Parts Breakdown: 09.2-1960-050 (3)

Data: N/A

Adjustment: N/A

Forward Switch

Diagrams: DIA-1961-002 DIA-1961-019

Location: right armrest

Parts Breakdown: 04.6-1960-001 (50)

Purpose: informs control system forward travel is being requested Data: N/A

HCS

Adjustment: N/A

Height Cable Switch

Diagrams: DIA-1961-002 DIA-1961-019

Location: mainframe base Purpose: provide limited travel speed if main mast height cable breaks or becomes slack

Parts Breakdown: 04.6-1960-001 (17)

Data: normally closed

GTSL

Adjustment: N/A

Gate Switch (Not Available on Narrow Rail)

Diagrams: DIA-1961-003 DIA-1961-018

Location: left gate Purpose: prevents lift, lower and traction if gates are open

Parts Breakdown: 07.0-1960-500 (6)

Data: normally closed Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-011 Parts Breakdown: 09.1-1960-001 (29)

GTSR Gate Switch (Not Available on Narrow Rail) Location: right gate Purpose: prevents lift, lower and traction if gates are open M1.0-1961-107 02 Rev. 12/09

100

TSP 6000 Series

Crown 2005 PF15321-59 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Figure 21404

Crown 2005 PF15321-60 Rev. 12/09

TSP 6000 Series

M1.0-1961-108 02 Rev. 12/09

101

LUBRICATION & ADJUSTMENT Switches HGTRS1

Adjustment: N/A

Main Height Reset Switch

Diagrams: DIA-1961-002 DIA-1961-020

Location: platform Purpose: resets counter in electronic system when platform is fully lowered Data: N/A

Parts Breakdown: 04.5-1960-001 (8)

HPSR Right Hand Presence Switch

Adjustment: N/A

Location: right armrest

Diagrams: DIA-1961-002 DIA-1961-009

Purpose: senses operator presence Data: N/A

Parts Breakdown: 09.0-1960-200 (32)

Adjustment: N/A

HGTRS2

Diagrams: DIA-1961-002 DIA-1961-019

Auxiliary Height Reset Switch

Parts Breakdown: 04.6-1960-001 (5)

Location: load handler Purpose: resets counter in electronic system when forks are lowered

KYS

Data: N/A

Key Switch

Adjustment: N/A

Location: console

Diagrams: DIA-1961-002 DIA-1961-023

Purpose: allows operator to power up truck or shut truck down

Parts Breakdown: 09.1-1960-350 (22) 09.1-1960-400 (21)

Data: N/A Adjustment: N/A

HNS

Diagrams: DIA-1961-002 DIA-1961-008

Horn Switch

Parts Breakdown: 04.5-1960-100 (4)

Location: right armrest Purpose: allows operator to sound horn Data: normally open Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-019 Parts Breakdown: 04.6-1960-001 (1)

HPSL Left Hand Presence Switch Location: left armrest Purpose: senses operator presence Data: N/A

M1.0-1961-109 02 Rev. 12/09

102

TSP 6000 Series

Crown 2005 PF15321-61 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Figure 21405

Crown 2005 PF15321-62 Rev. 12/09

TSP 6000 Series

M1.0-1961-110 02 Rev. 12/09

103

LUBRICATION & ADJUSTMENT Switches LGS1

Diagrams: DIA-1961-002 DIA-1961-020

Dome Light Switch

Parts Breakdown: 04.5-1960-001 (7)

Location: console Purpose: allows operator to turn dome light ON or OFF Data: N/A

PLS Pivot Left Switch Location: left armrest

Adjustment: N/A

Purpose: controls mechanical limit of pivot function to the left

Diagrams: DIA-1961-008 Parts Breakdown: 04.5-1960-100 (12)

Data: N/A Adjustment: N/A

LGS2 Work Light Switch

Diagrams: DIA-1961-002 DIA-1961-020

Location: console

Parts Breakdown: 04.5-1960-001 (7)

Purpose: allows operator to turn work lights ON or OFF

PRS

Data: N/A

Pivot Right Switch

Adjustment: N/A

Location: left armrest

Diagrams: DIA-1961-008

Purpose: controls mechanical limit of pivot function to the right

Parts Breakdown: 04.5-1960-100 (15)

Data: N/A

LGS3

Adjustment: N/A

Work Light Switch (Optional)

Diagrams: DIA-1961-002 DIA-1961-020

Location: console Purpose: allows operator to turn spot light ON or OFF

Parts Breakdown: 04.5-1960-001 (7)

Data: N/A Adjustment: N/A Diagrams: DIA-1961-008 Parts Breakdown: 04.5-1960-100 (11)

ORS1 Override Switch Location: left armrest Purpose: when raise lower cutout programmed for override is encountered, actuating switch permits continuation of function, provides optional EAC override Data: N/A Adjustment: N/A

M1.0-1961-111 02 Rev. 12/09

104

TSP 6000 Series

Crown 2005 PF15321-63 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Figure 21406

Crown 2005 PF15321-64 Rev. 12/09

TSP 6000 Series

M1.0-1961-112 02 Rev. 12/09

105

LUBRICATION & ADJUSTMENT Switches RGSL

Data: normally open Adjustment: N/A

Rail Guide Switch (Optional) Location: aisle guide wheel bracket mounted under power unit Purpose: provide ability to turn ON automatic steering Data: N/A

Diagrams: DIA-1961-002 DIA-1961-019 Parts Breakdown: 04.6-1960-001 (1)

SES

Adjustment: N/A

Seat Sense Switch

Diagrams: DIA-1961-003 DIA-1961-014

Location: seat Purpose: sense operator presence on seat

Parts Breakdown: 10.4-1960-001 (17) 10.4-1960-050 (16)

Data: normally open Adjustment: N/A

RGSR

Diagrams: DIA-1961-002 DIA-1961-011

Rail Guide Switch (Optional) Location: aisle guide wheel bracket mounted under power unit

Parts Breakdown: 09.0-1960-150 (9)

Purpose: provide ability to turn ON automatic steering

SLS

Data: N/A

Seat Sense Switch

Adjustment: N/A

Location: seat

Diagrams: DIA-1961-003 DIA-1961-014

Purpose: sense when seat is locked in place Data: normally closed

Parts Breakdown: 10.4-1960-001 (17) 10.4-1960-050 (16)

Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-011

Parts Breakdown: 09.0-1960-150 (112)

Reverse Switch Location: right armrest Purpose: informs traction controller reverse travel direction is being requested Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-019 Parts Breakdown: 04.6-1960-001 (17)

RSS Release Seat Switch Location: right armrest Purpose: release seat lock M1.0-1961-113 02 Rev. 12/09

106

TSP 6000 Series

Crown 2005 PF15321-65 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

(located on opposite side)

Figure 21407

Crown 2005 PF15321-66 Rev. 12/09

TSP 6000 Series

M1.0-1961-114 02 Rev. 12/09

107

LUBRICATION & ADJUSTMENT Switches SPS

Diagrams: DIA-1961-002 DIA-1961-023

Seat Position Switch

Parts Breakdown: 09.1-1960-100 (6)

Location: seat

ZSS

Purpose: sense when seat is forward facing Data: normally closed

Zone Select Switch (Optional)

Adjustment: N/A

Location: console

Diagrams: DIA-1961-002 DIA-1961-011

Purpose: allows selection of lift height cutout Data: N/A

Parts Breakdown: 09.0-1960-150 (112)

Adjustment: N/A

TBS

Diagrams: DIA-1961-002 DIA-1961-008

Tilt Back Switch (Optional)

Parts Breakdown: 04.5-1960-100 (2)

Location: right armrest Purpose: allows operator to select tilt back function Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-019 Parts Breakdown: 04.6-1960-001 (1)

TDS Tilt Down Switch Location: right armrest Purpose: allows operator to select tilt down function Data: N/A Adjustment: N/A Diagrams: DIA-1961-002 DIA-1961-019 Parts Breakdown: 04.6-1960-01 (1)

TVRS Traverse Reset Switch Location: load handler Purpose: verify and reset traverse encoder count, ECR4 Data: N/A Adjustment: N/A

M1.0-1961-115 02 Rev. 12/09

108

TSP 6000 Series

Crown 2005 PF15321-67 Rev. 12/09

LUBRICATION & ADJUSTMENT Switches

Figure 21408

TSP 6000 Series

M1.0-1961-116 02 Rev. 12/09

109

LUBRICATION & ADJUSTMENT Metric Torque Values

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

Grade

Grade Marking (on Head)

Specification Class 5.8 Class 8.8 Class 10.9

Material

Bolt and Screw Size (mm)

Low Carbon Steel

M5 through M36

Medium Carbon Steel Quenched and Tempered

M5 through M36

Medium Carbon Alloy Steel Quenched and Tempered

M5 through M36

Note: Even though a bolt head is unmarked, Crown uses nothing less than class 8.8 in all of its bolted assemblies. Instances do occur when class 8.8 bolts are manufactured unmarked. When a fastener is replaced that is unmarked, replace the fastener with a class 8.8.

Figure 15048

M1.9-06.6-001 02 Rev. 11/08

110

TSP 6000 Series

Crown 1989 PF8514-1 Rev. 11/08

LUBRICATION & ADJUSTMENT Metric Torque Values

Torque Chart - Metric Hex Head Cap Screws and Nuts Tightening Torque Nm (ft lb)

Thread Diameter & Pitch

Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

5 - 8 (4 - 6)

7 - 8 (5 - 6)

8 - 10 (6 - 7)

M6 x 1.00

8 - 10 (6 - 7)

12 - 14 (9 - 10)

15 - 16 (11 - 12)

M8 x 1.25

20 - 25 (15 - 18)

28 - 31 (21 - 23)

34 - 37 (25 - 27)

M10 x 1.50

39 - 43 (29 - 32)

56 - 61 (41 - 45)

68 - 75 (50 - 54)

M12 x 1.75

71 - 76 (52 - 56)

100 - 107 (73 - 79)

119 - 127 (88 - 94)

M14 x 2.00

113 - 122 (83 - 90)

159 - 171 (117 - 126)

190 - 205 (140 - 151)

M16 x 2.00

175 - 190 (129 - 140)

247 - 267 (182 - 197)

296 - 320 (218 - 236)

M20 x 2.50

340 357 (251 - 271)

479 - 518 (353 - 382)

574 - 621 (423 - 458)

M24 x 3.00

587 - 635 (433 - 468)

824 - 892 (608 - 658)

990 - 1071 (730 - 790)

M30 x 3.50

1175 - 1274 (867 - 940)

1654 - 1792 (1220 - 1322)

1985 - 2150 (1464 - 1586)

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

Torque Chart - Metric Hex Socket Countersink Head Screws Tightening Torque Nm (ft lb)

Thread Diameter & Pitch

Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

4 - 7 (3 - 5)

5 - 8 (4 - 6)

7 - 10 (5 - 7)

M6 x 1.00

7 - 10 (5 - 7)

9 - 12 (7 - 9)

11 - 14 (8 - 10)

M8 x 1.25

16 - 19 (12 - 14)

23 - 26 (17 - 19)

27 - 30 (20 - 22)

M10 x 1.50

31 - 34 (23 - 25)

45 - 49 (33 - 36)

54 - 58 (40 - 43)

M12 x 1.75

56 - 60 (41 - 44)

79 - 84 (58 - 62)

94 - 102 (69 - 75)

M16 x 2.00

124 - 146 (99 - 108)

190 - 206 (140 - 152)

228 - 247 (168 - 182)

M20 x 2.50

259 - 281 (191 - 207)

363 - 395 (268 - 291)

437 - 473 (322 - 349)

M24 x 3.00

416 - 451 (307 - 333)

586 - 635 (432 - 468)

702 - 762 (518 - 562)

M14 x 2.00

M30 x 3.50 Note: Torque values called out in the maintenance section of this manual will take precedence over torque values found on this page.

Crown 1989 PF8514-2 Rev. 11/08

TSP 6000 Series

M1.9-06.6-002 02 Rev. 11/08

111

LUBRICATION & ADJUSTMENT Metric Torque Values

Torque Chart - Metric Socket Head Cap Screws Tightening Torque Nm (ft lb)

Thread Diameter & Pitch

Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

5 - 8 (4 - 6)

7 - 9 (5 - 7)

8 - 11 (6 - 8)

M6 x 1.00

9 - 12 (7 - 9)

12 - 15 (9 - 11)

15 - 18 (11 - 13)

M8 x 1.25

22 - 24 (16 - 18)

30 - 33 (22 - 24)

35 - 38 (26 - 28)

M10 x 1.50

42 - 45 (31 - 33)

58 - 64 (43 - 47)

71 - 76 (52 - 56)

M12 x 1.75

72 - 77 (53 - 57)

102 - 110 (75 - 81)

122 - 132 (90 - 97)

M14 x 2.00

115 - 125 (85 - 92)

161 - 175 (119 - 129)

194 - 210 (143 - 155)

M16 x 2.00

179 - 194 (132 - 143)

251 - 273 (185 - 201)

301 - 327 (222 - 241)

M20 x 2.50

348 - 377 (257 - 278)

489 - 530 (361 - 391)

588 - 637 (434 - 470)

M24 x 3.00

601 - 651 (443 - 480)

846 - 915 (624 - 675)

1014 - 1098 (748 - 810)

M30 x 3.50

1196 - 1296 (882 - 956)

1681 - 1822 (1240 - 1344)

2017 - 2187 (1488 - 1613)

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

Torque Chart - Metric Flanged Hex Head Cap Screws and Nuts Thread Diameter & Pitch

Tightening Torque Nm (ft lb) Class 8.8

Class 10.9

Class 12.9

M5 x 0.80

8 - 11 (6 - 8)

9 - 12 (7 - 9)

M6 x 1.00

14 - 16 (10 - 12)

16 - 19 (12 - 14)

M8 x 1.25

31 - 34 (23 - 25)

38 - 41 (28 - 30)

M10 x 1.50

62 - 68 (46 - 50)

75 - 81 (55 - 60)

M12 x 1.75

108 - 117 (80 - 86)

130 - 141 (96 - 104)

M14 x 2.00

174 - 187 (128 - 138)

209 - 225 (154 - 166)

M16 x 2.00

273 - 294 (201 - 217)

327 - 354 (241 - 2610

M20 x 2.50 Note: Torque values called out in the maintenance section of this manual will take precedence over torque values found on this page.

M1.9-06.6-003 02 Rev. 11/08

112

TSP 6000 Series

Crown 1989 PF8514-3 Rev. 11/08

LUBRICATION & ADJUSTMENT Torque Values

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

Grade Grade Marking (on Head)

Specification SAE - Grade 2

Material Low Carbon Steel

Bolt and Screw Size (Inches) 1/4 thru 1-1/2

SAE - Grade 5

Medium Carbon Steel, Quenched and Tempered

1/4 thru 1-1/2

SAE - Grade 8

Medium Carbon Alloy Steel, Quenched and Tempered

1/4 thru 1-1/2

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

Figure 14916

Crown 1979 PF5067-1 Rev. 9/06

TSP 6000 Series

M1.9-14.0-001 04 Rev. 9/06

113

LUBRICATION & ADJUSTMENT Torque Values

Torque Chart Bolt Diameter

Grade 5

Grade 8

Dry Torque Requirement

ft Ib

kgm

ft lb

kgm

1/4

9±3

1.2 ± .4

12 ± 4

13 ± 4

1.8 ± .5

17.5 ± 5.5

5/16

18 ± 5

2.5 ± .7

24.5 ± 7

25 ± 5

3.5 ± .7

34 ± 7

3/8

32 ± 5

4.4 ± .7

43.5 ± 7

48 ± 10

6.6 ± 1.3

65 ± 13.5

7/16

50 ± 10

6.9 ± 1.4

67.5 ± 13.5

75 ± 10

10.4 ± 1.4

102 ± 13.5

1/2

75 ± 10

10.4 ± 1.4

101.5 ± 13.5

112 ± 15

15.5 ± 2.0

152 ± 20.5

9/16

110 ± 15

15.2 ± 2.0

149 ± 20.5

163 ± 20

22.5 ± 3.0

221 ± 27

5/8

150 ± 20

20.7 ± 2.8

203.5 ± 27

225 ± 30

31.1 ± 4.1

305 ± 41

3/4

265 ± 35

36.6 ± 4.8

359 ± 47.5

400 ± 50

55.2 ± 6.9

542 ± 68

7/8

420 ± 60

58.1 ± 8.3

569 ± 81

640 ± 80

88.3 ± 11.0

868 ± 108

640 ± 80

88.5 ± 11.1

868 ± 109

960 ± 115

132.5 ± 15.9 1300 ± 156

1 1/8

800 ± 100

110.6 ± 13.8 1085 ± 136

1 1/4

1000 ± 120

138 ± 16.6

1356 ± 163

1 3/8

1200 ± 150

166 ± 20.7

1630 ± 203

1 1/2

1500 ± 200

207 ± 27.7

2034 ± 271

Mounting bolt torque requirements involving hydraulic valves. 5/16

13 ± 2

1.8 ± .3

17.5 ± 2.5

3/8

24 ± 2

3.3 ± .3

32.5 ± 2.5

7/16

39 ± 2

5.4 ± .3

53 ± 2.5

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

M1.9-14.0-002 04 Rev. 9/06

114

TSP 6000 Series

Crown 1979 PF5067-2 Rev. 9/06

HYDRAULIC SYSTEM

115

Notes:

116

HYDRAULIC SYSTEM General Information

General Information

Hydraulic Lines and Fittings

The hydraulic system in your truck is powered by a gear type pump driven by a three phase AC motor. The pump, P1, supplies oil flow for lift and accessory functions.

•

Blow air through all hose and lines to remove loose particles before installing. Any rubber hose with wire braid inner construction and any steel tube lines which have been collapsed or kinked are permanently damaged and must be replaced even if the damage is not externally visible.

•

Flexible hose must be replaced if it collapses in normal operating position.

•

All hoses and lines are to be clear of any surface or edge which will cause damaging wear and cuts, or on which they can become caught.

•

All connections are to be leak free.

•

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

Maximum pressure is limited by an adjustable relief valve, RV1, (refer to section M2.4). The setting for RV1 is noted on the hydraulic schematics. Refer to the service manual index for pump, valve and manifold information. Should it be necessary to lower the operator compartment in an emergency or for service, this can be done by operating the manual lowering valve even with battery disconnected.

WARNING Before using Manual Lowering Valve warn operator to keep all body members within the operator compartment. Make sure the forks are clear of the rack. Close valve immediately if chains become slack.

WARNING AVOID HIGH PRESSURE FLUIDS—Escaping fluid under pressure can penetrate the skin causing serious injury. • Relieve pressure before disconnecting hydraulic lines. • Tighten all connections before applying pressure.

•

Crown 2005 PF15099-1 Rev. 6/06

Reservoir With all cylinders in the retracted position and after all air has been bled from the hydraulic system, fill reservoir so that the oil level is to the "FULL" mark on dipstick. The dipstick is located with the breather assembly (1) in reservoir. Refer to Figure 12872. The total capacity of the hydraulic system at this level should be approximately 47 litres (12.5 gallons). The hydraulic system is very susceptible to dirt and contamination that could, overtime, create hydraulic malfunctions. Therefore, before adding oil to truck, filter oil with a 10 micron filter or with a 100 mesh strainer. This is especially important when oil source is a 55 gallon drum.

TSP 6000 Series

M2.0-1960-001 01 Rev. 6/06

117

HYDRAULIC SYSTEM General Information Filter

Lift Drift Test

The internal filter is contained within the reservoir filter assembly (2). Refer to Figure 12872. To access filter remove the (3) screws from cap. Grasp inner support tube and remove. The filter element can be removed from the support tube and replaced. Insert filter element and support tube into assembly. Replace cap and tighten screws. Filter element may be incinerated for disposal.

Elevate the test load on the auxiliary mast approximately 305 to 610 mm (1 to 2 ft) and raise the operator compartment until the second stage mast has raised approximately 610 to 915 mm (2 to 3 ft). Shut off truck. After five minutes, measure the distance the forks have drifted. Drifting in excess of 13 mm (0.50 in) per minute, over a period of five minutes (64 mm [2.50 in] total drift) is considered unacceptable. Occasionally, a slight creep of the fork assembly may occur due to internal leakage in the piston pak, but it can also be caused by leakage in check or control valve. To seat these valves properly when this occurs, raise and lower the forks to flush out any foreign material from the valve seat. A thorough check for leaks in the system should be conducted if abnormal oil losses occur. The hydraulic system is designed to eliminate mechanical damage even if fittings become loose.

Figure 12872

Drift Test All drift test should be conducted with a capacity load (refer to serial plate for the rated capacity of your truck). The material used for the test load must be evenly stacked within the limits of a four foot square pallet and must be secured to the fork carriage with forks spread to their maximum width.

NOTE The lift measurement is to be taken from the tip of the fork to the floor.

CAUTION Never stand or work under a suspended load.

M2.0-1960-002 01 Rev. 6/06

118

TSP 6000 Series

Crown 2005 PF15099-2 Rev. 6/06

HYDRAULIC SYSTEM General Information Freezer Preparation Crown trucks may require a mixture of low temperature hydraulic oil, Crown P/N 063001-006 (gal.), blended with standard hydraulic oil, Crown P/N 063001-021 (gal.) when used in a freezer or cooler. 100% low temperature oil is too thin for most cold storage operations and therefore could shorten the life of cylinder packings and pumps if used in higher ambient temperatures.

NOTE Trucks equipped with velocity fuses may experience staging issues if an insufficient mix of low temperature oil has been used. For truck applications operating continually in temperatures at or above 0 °C (32 °F), use 100% standard hydraulic oil (063001-001) (1). Refer to Figure 12873. For truck applications operating continually at temperatures of 0 °C (32 °F) or below, use an 80/20 blend, 80% low temperature (063001-006) and 20% standard hydraulic oil (063001-021) (2). Refer to Figure 12873. The proper mixture of freezer hydraulic oil will ensure the best and most efficient operation of your Crown equipment.

Figure 12873-01

Crown 2005 PF15099-3 Rev. 6/06

TSP 6000 Series

M2.0-1960-003 01 Rev. 6/06

119

HYDRAULIC SYSTEM Hydraulic Circuits

Hydraulic Circuits

flow to PCBy and PVMR. Pilot pressure is delivered to the bottom of PCBy.

These pages contain a brief description of the hydraulic circuits for TSP 6000 trucks which are typical of current standard units. Your unit may vary. Refer to section HYD in this manual for appropriate schematic.

Main Lift Circuit PVMR is the proportional valve for main lift and is electrically controlled by Access 2. The more voltage applied to PVMR coil, the more PVMR spool moves which permits more oil to flow to the main lift cylinder(s). When an operator requests main lift, oil flows from the pump through manifold port P to RV1 and PCA. RV1 is an adjustable relief valve that protects the circuit from excessive pressure. A pilot line delivers oil pressure to the right side of PCA. When pilot pressure exceeds PCA spring force, oil pressure causes PCA spool to shift left permitting oil to

PVMR is opened in proportion to the operator command and allows oil to flow through CV2 out port C1 and into the lift cylinders. Pilot pressure is delivered to the top of PCBy through ORF2. If PVMR is not fully opened then a pressure differential will exist across PVMR. If the pressure before PVMR exceeds PCBy’s spring force and the pilot pressure ported to the top of PCBy, then PCBy will open and allow oil to return to the reservoir. The amount of oil returning to the reservoir via PCBy is proportional to the difference in pressure across PVMR. This permits full pressure compensation of the lift flow. With the same operator command to PVMR, the same flow will be delivered out port C1 regardless of load weight or pressure. It also provides for a smooth stop and start by preventing a sudden spike or drop in pressure should the operator suddenly stop and start raising the platform. When lift is stopped and PVMR is de-energized, ORF4 permits pilot pressure to PCBy to be bled off to reservoir through port T.

Main Frame Manifold

SUCTION PRESSURE RETURN PILOT PRESSURE RV1 set @ 24.8 MPa (3600 psi)

Figure 12874

M2.0-1960-004 01 Rev. 6/06

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TSP 6000 Series

Crown 2005 PF15099-4 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits Main Lower Circuit The weight of the platform, load handler and load produces pressure in the circuit. Pressure is supplied to PVML and MPV. Pilot pressure is delivered through ORF5 to the right side of PCML causing PCML’s spool to move left. ORF5’s purpose is to slow PCML’s response causing smooth lowering. PCML and PVML are not “no leak” valves so a small amount of oil can flow past their spools causing the platform to lower very slowly due to drift. SVML is a “no leak” valve and prevents drift. When an operator requests main lower, Access 2 energizes SVML. As SVML is opened and with PVML still closed, any pressure in the circuit after PCML is relieved. Access 5 then opens PVML in proportion to the operator command to control lower speed. When PVML is opened, oil flows to PCML and applies pilot pressure to the left side of PCML. The spring in PCML and the pilot pressure delivered to the left side of PCML moves PCML’s spool right and holds PCML

open to allow a path for return oil. If the pressure differential across PVML is greater than PCML’s spring force, the pilot pressure delivered to the right side of PCML will cause PCML to gradually close. Because of this, the flow across PVML and PCML will remain constant for a given command regardless of load weight or pressure at port C1 of the manifold assembly providing pressure compensated lower control. For example, a capacity load will cause greater system pressure then a load 10% of capacity but can be lowered at the same speed if the lower command (movement of the multitask handle) is the same. The reason for this is pilot pressure delivered to the right side of PCML will be greater for the capacity load and more fully close PCML. Maximum lower speed is controlled by the maximum opening of PVML. PVML’s position is electronically controlled by Access 2 giving Access 2 electronic control of lower speed. Lower speed, as controlled by Access 2, can be modified in the Performance menu. Oil flows through PCML, SVML, out port T of the main frame manifold and returns to the reservoir.

Main Frame Manifold

SUCTION PRESSURE RETURN PILOT PRESSURE RV1 set @ 24.8 MPa (3600 psi)

Figure 12875

Crown 2005 PF15099-5 Rev. 6/06

TSP 6000 Series

M2.0-1960-005 01 Rev. 6/06

121

HYDRAULIC SYSTEM Hydraulic Circuits Main Lower Circuit (MVL) Opening the manual lower valve located at the back of the power unit will lower the platform. Pull handle to open valve. The further the handle is pulled the faster the platform will lower.

WARNING

ment. Make sure the forks are clear of the rack. Close valve immediately if chains become slack. Do not allow anyone to stand under platform when lowering. The weight of the platform, load handler and load produces pressure in the circuit. Pressure is supplied to MVL. When MVL is opened, a path for oil flow is created for return oil to flow through MVL and out port T to the reservoir.

Before using Manual Lowering Valve, warn operator to keep all body members within the operator’s compart-

Main Frame Manifold

SUCTION PRESSURE RETURN PILOT PRESSURE RV1 set @ 24.8 MPa (3600 psi)

Figure 12876

M2.0-1960-006 01 Rev. 6/06

122

TSP 6000 Series

Crown 2005 PF15099-6 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits Load Handler Circuit through Main Frame Manifold

reservoir. Oil flows through manifold port P to RV1. Oil is directed through SP1, PCA and CV1 and out the main frame manifold through port A to the load handler manifold.

(Except Auxiliary Lower) SP1 is a proportional control valve that directs oil for all auxiliary (load handler) functions. Access 2 controls SP1 by varying the applied voltage to the SP1 coil. The more voltage applied to SP1 coil, the more SP1 spool moves which permits more oil to flow to the auxiliary functions. Actuating SP1 for any load handler function causes PCA to adjust to provide priority flow to the load handler manifold. Any unused oil is passed out to the secondary port to PCBy and PVMR. The requested flow out SP1 is directed to the load handler through PCA, and excess flow is directed to PCBy and PVMR. When an operator requests an auxiliary function(s), Access 2 energizes SP1 coil opening the valve in proportion to the operator’s request and turns on the variable speed pump motor causing P1 to draw oil from the

SP1 and PCA control the amount of oil flow to the load handler manifold. Oil flow before SP1 and after SP1 is applied through pilot passages to both sides of PCA. If SP1 is opened a small amount, more oil will flow through pilot passages to PCA’s right side. When that oil flow creates enough pressure to overcome the spring force on PCA’s left, PCA will shift left allowing some oil to be directed to PCBy and PVMR and may be used for main lift (if requested) or directed back to the reservoir by PCBy. If SP1 is opened fully, just the opposite will happen. More oil will flow into the pilot passages on PCA’s left and assist the spring in moving PCA to the right, sending more oil to the load handler manifold. When the accessory function is no longer requested, pressure before CV1 is bled through ORF1.

Main Frame Manifold

SP1 Energized, Flow to Port A, Limited Flow to PCBy, PVMR

SP1 De-Energized, Flow “Bypass” to PCBy & PVMR DETAIL A

to Load Handle Manifold SUCTION PRESSURE RETURN PILOT PRESSURE

RV1 set @ 24.8 MPa (3600 psi)

Figure 12877-01 Crown 2005 PF15099-7 Rev. 6/06

TSP 6000 Series

M2.0-1960-007 01 Rev. 6/06

123

HYDRAULIC SYSTEM Hydraulic Circuits Auxiliary Lift Circuit PVAR is the auxiliary raise proportional valve providing proportional control of the load handler raise function. Access 7 controls PVAR position by varying the applied voltage to the coil. The more voltage applied to PVAR coil, the more PVAR spool moves permitting more oil to flow to the load handler lift cylinder. When an operator requests auxiliary raise, Access 7 energizes PVAR coil opening the valve in proportion to operator’s request. Access 7 also energizes PVLH coil adjusting the auxiliary relief pressure setting up to 24.1 MPa (3500 psi) (PVLH is an electronic proportional pilot operated relief valve providing proportional control of the auxiliary relief pressure setting. It adjusts to supply appropriate pressure based on feedback from the load sense pressure transducer, LS.). Oil flows out of the main manifold into port AP of the auxiliary manifold block, to PVLH and through PCAR. PVAR is opened in proportion to the operator command and allows oil to flow through CV3 out port AH and into the load handler lift cylinder. Oil also flows to the load sensor pressure transducer, LS, which senses the pressure applied to the system from a load.

Pilot pressure is delivered to both sides of PCAR and is sensed from both sides of PVAR. If PVAR is not fully opened then a pressure differential will exist across PVAR. If pilot pressure sensed after PVAR exceeds PCAR spring force and the pilot pressure sensed before PVAR, then PCAR spool will shift left restricting flow to PVAR and increasing pressure to PVLH which relieves the pressure by directing the oil flow to the reservoir. This permits full pressure compensation of the auxiliary lift circuit. With the same operator command to PVAR, the same flow will be delivered out port AH regardless of load weight or pressure. It also provides for a smooth stop and start by preventing a sudden spike or drop in pressure should the operator suddenly stop and start raising the forks. When lift is stopped and PVAR is de-energized, ORF7 permits pilot pressure sensed after PCAR to be bled off to reservoir through port AT. Also, when lift is stopped and PVLH is de-energized, PVLH’s pressure setting reduces to spring force (set at 1.38 MPa [200 psi]) and allows oil pressure before PVAR to be bled down to 1.38 MPa (200 psi).

Part of Load Handler Manifold

SUCTION PRESSURE RETURN PILOT PRESSURE

from Main Frame Manifold

to Reservoir

Figure 12878-01

M2.0-1960-008 01 Rev. 6/06

124

TSP 6000 Series

Crown 2005 PF15099-8 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits Auxiliary Lower Circuit When an operator requests auxiliary lower, Access 7 energizes SVAL to allow return oil flow. The weight of the forks and load produces pressure in the circuit. Pilot pressure is delivered through ORF6 to PCAL. ORF6’s purpose is to slow PCAL’s response causing smooth lowering. Access 7 then energizes PVAL, with PVAL opening in proportion to the operator command to control lower speed. During auxiliary lower, oil flows from the lift cylinder to port AH of the auxiliary hydraulic manifold, through PVAL, PCAL, out port AT of the auxiliary hydraulic manifold and returns to the reservoir. When PVAL is opened, the spring in PCAL and the pilot pressure delivered to the right side of PCAL holds PCAL open to allow lower. If the pressure differential before PVAL is greater than PCAL’s spring force and the pilot pressure after PVAL, the pilot pressure delivered to the left side of PCAL will cause PCAL to gradually close. Because of this, the flow across PVAL and

PCAL will remain constant for a given command regardless of load weight or pressure at port AH of the manifold assembly providing pressure compensated lower control. For example, a capacity load will cause greater system pressure then a load 10% of capacity but can be lowered at the same speed if the lower command (movement of the multi-task handle) is the same. The reason for this is pilot pressure delivered to the left side of PCAL will be greater for the capacity load and more fully close PCAL. Maximum auxiliary lower speed is controlled by the maximum opening of PVAL. PVAL’s position is electronically controlled by Access 7 giving Access 7 electronic control of lower speed. Lower speed, as controlled by Access 7, can be modified in the Performance menu. SVAL acts as a velocity fuse. If the lowering speed reading from the auxiliary height encoder exceeds 36.5 m/min (120 ft/min), SVAL will be de-energized stopping the lift cylinder from lowering.

Part of Load Handler Manifold

SUCTION PRESSURE RETURN PILOT PRESSURE

from Main Frame Manifold

to Reservoir

Figure 12879

Crown 2005 PF15099-9 Rev. 6/06

TSP 6000 Series

M2.0-1960-009 01 Rev. 6/06

125

HYDRAULIC SYSTEM Hydraulic Circuits Traverse Left Circuit PVT provides proportional control of the traverse function. When traversing right, S1 coil is energized, moving PVT spool right and when traversing left, S2 coil is energized moving PVT spool left (S1 is the top coil and S2 is the bottom coil). Access 7 controls PVT by varying the applied voltage to the coils. The more voltage applied to PVT coils, the more PVT spool moves which permits more oil to flow to the traverse motor. Two valves in the load handler manifold control the pressure setting for the traverse circuit, PVLH and PR1. When traverse only is requested, the valve pressure settings are the same so the valves perform the same function. However, when more than one load handler function is requested, pressure settings may be different. For example, if auxiliary lift and traverse are selected, PVLH will be electronically adjusted by Access 7 up to 24.1 MPa (3500 psi) to ensure adequate pressure for lift while PR1 is factory set to limit the pressure to 16.5 MPa (2400 psi) to ensure proper pressure for traverse.

Pilot pressure is delivered to both sides of PCT and is sensed from pressure across PVT. If PVT is not fully opened, a pressure differential will exist across PVT. If pilot pressure sensed before PVT exceeds PCT’s spring force and the pilot pressure sensed at the load sense port of PVT, then PCT spool will shift right reducing flow into PVT. This permits full pressure compensation of the traverse circuit. With the same operator command to PVT, the same flow will be delivered out port T2 regardless of load weight or pressure. It also provides for a smooth stop and start by preventing a sudden spike or drop in pressure should the operator suddenly stop and start traversing.

When an operator requests traverse left, Access 7 energizes PVT S2 coil shifting the valve spool in proportion to operator’s request. Access 7 also energizes PVLH coil adjusting the pressure setting to 9.7 MPa (1400 psi). Oil flows from the main frame manifold into port AP of the load handler manifold to PVLH. PVLH pilot line senses the pressure and if the pressure is greater than 9.7 MPa (1400 psi), PVLH’s spool will move and divert some of the flow to the reservoir. As oil flows through PR1, pilot pressure is delivered to the left side of PR1. If pressure is greater than 16.6 MPa (2400 psi), pilot pressure will overcome spring force and shift PR1’s spool to the right restricting flow to PCT limiting the pressure to 16.6 MPa (2400 psi). Oil flows through PCT, PVT to CBV1. Pressure is diverted to CBV2 through a pilot line. Oil flows through CBV1, out port T2 and into the traverse motor. Return oil flows from the traverse motor through CBV2’s upper pilot line shifting CBV2’s spool and creating a path for return oil. Oil flows through CBV2, PVT, CV4, out port AT of the load handler manifold and to the reservoir. After a load handler function is no longer requested, CV4 works in conjunction with CV1 (in the main frame manifold) to maintain approximately 1.38 MPa (200 psi) in the circuit to obtain a fast response.

M2.0-1960-010 01 Rev. 6/06

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TSP 6000 Series

Crown 2005 PF15099-10 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits

Part of Load Handler Manifold

SUCTION PRESSURE RETURN PILOT PRESSURE

from Main Frame Manifold

to Reservoir

Figure 12880

Crown 2005 PF15099-11 Rev. 6/06

TSP 6000 Series

M2.0-1960-011 01 Rev. 6/06

127

HYDRAULIC SYSTEM Hydraulic Circuits Traverse Right Circuit PVT provides proportional control of the traverse function. When traversing right, S1 coil is energized, moving PVT spool right and when traversing left, S2 coil is energized moving PVT spool left (S1 is the top coil and S2 is the bottom coil). Access 7 controls PVT by varying the applied voltage to the coils. The more voltage applied to PVT coils, the more PVT spool moves which permits more oil to flow to the traverse motor.

sense port of PVT, then PCT spool will shift right reducing flow into PVT. This permits full pressure compensation of the traverse circuit. With the same operator command to PVT, the same flow will be delivered out port T1 regardless of load weight or pressure. It also provides for a smooth stop and start by preventing a sudden spike or drop in pressure should the operator suddenly stop and start traversing.

Two valves in the load handler manifold control the pressure setting for the traverse circuit, PVLH and PR1. When traverse only is requested, the valve pressure settings are the same so the valves perform the same function. However, when more than one load handler function is requested, pressure settings may be different. For example, if auxiliary lift and traverse are selected, PVLH will be electronically adjusted by Access 7 up to 24.1 MPa (3500 psi) to ensure adequate pressure for lift while PR1 is factory set to limit the pressure to 16.6 MPa (2400 psi) to ensure proper pressure for traverse. When an operator requests traverse right, Access 7 energizes PVT S1 coil shifting the valve spool in proportion to operator’s request. Access 7 also energizes PVLH coil adjusting the pressure setting to 9.7 MPa (1400 psi). Oil flows from the main frame manifold into port AP of the load handler manifold to PVLH. PVLH pilot line senses the pressure and if the pressure is greater than 9.7 MPa (1400 psi), PVLH’s spool will move and divert some of the flow to the reservoir. As oil flows through PR1, pilot pressure is delivered to the left side of PR1. If pressure is greater than 16.6 MPa (2400 psi), pilot pressure will overcome spring force and shift PR1’s spool to the right restricting flow to PCT limiting the pressure to 16.6 MPa (2400 psi). Oil flows through PCT, PVT to CBV2. Pressure is diverted to CBV1 through a pilot line. Oil flows through CBV2, out port T1 and into the traverse motor. Return oil flows from the traverse motor through CBV1’s upper pilot line shifting CBV1’s spool and creating a path for return oil. Oil flows through CBV1, PVT, CV4, out port AT of the load handler manifold and to the reservoir. After a load handler function is no longer requested, CV4 works in conjunction with CV1 (in the main frame manifold) to maintain approximately 1.38 MPa (200 psi) in the circuit to obtain a fast response. Pilot pressure is delivered to both sides of PCT and is sensed from pressure across PVT. If PVT is not fully opened, a pressure differential will exist across PVT. If pilot pressure sensed before PVT exceeds PCT’s spring force and the pilot pressure sensed at the load

M2.0-1960-012 01 Rev. 6/06

128

TSP 6000 Series

Crown 2005 PF15099-12 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits

Part of Load Handler Manifold

SUCTION PRESSURE RETURN PILOT PRESSURE

from Main Frame Manifold

to Reservoir

Figure 12881

Crown 2005 PF15099-13 Rev. 6/06

TSP 6000 Series

M2.0-1960-013 01 Rev. 6/06

129

HYDRAULIC SYSTEM Hydraulic Circuits Fork Extend Circuit PVF is the proportional valve that controls the fork extend function. When extending the forks, S1 coil is energized moving PVF spool to the left and when retracting the forks, S2 coil is energized moving PVF spool to the right (S1 is the top coil and S2 is the bottom coil). Access 7 controls PVF by varying the applied voltage to the coils. The more voltage applied to PVF coils, the more PVF spool moves which permits more oil to flow to the forks. Two valves in the load handler manifold control the pressure setting for the fork extend circuit, PVLH and PR2. When fork retract only is requested, the valve pressure settings are the same so the valves perform the same function. However, when more than one load handler function is requested, pressure settings may be different. For example, if auxiliary lift and fork retract are selected, PVLH will be electronically adjusted by Access 7 up to 24.1 MPa (3500 psi) to ensure adequate pressure for lift, while PR2 is factory set to limit maximum pressure to 9.7 MPa (1400 psi) to ensure proper pressure for fork retract.

M2.0-1960-014 01 Rev. 6/06

130

When an operator requests fork extend, Access 7 energizes PVF S1 coil shifting the valve spool in proportion to operator’s request. Access 7 also energizes PVLH coil adjusting the pressure setting to 9.7 MPa (1400 psi). Oil flows from the main frame manifold into port AP of the load handler manifold and to PVLH. PVLH pilot line senses pressure and if pressure is greater than 9.7 MPa (1400 psi) will move PVLH’s spool and divert some of the flow to reservoir. Oil flows through PR2. Pilot pressure is delivered to the top of PR2. If pressure is greater than 9.7 MPa (1400 psi), pilot pressure will overcome spring force and gradually move PR1’s spool down restricting flow to PVF limiting pressure to 9.7 MPa (1400 psi). Oil flows through PVF, out port F2 and into the fork extend manifold. Oil flows through a pilot line to SPC1 unseating the single pilot check valve permitting a path for return flow from the forks. Oil flows through SPC2, through the flow divider control valve (restricted) FDC, out manifold ports C3 and C4 and into the front of the forks. Pilot pressure is delivered to both flow divider restrictions and is sensed from pressure on opposite sides of the restrictions. If a pressure differential exists across the restrictions, pilot pressure will adjust the restrictions to equalize the pressure to each fork ensuring equal movement of the rams. Return oil flows from the rear of the forks, through ports C1 and C2 of the fork extend manifold, through SPC1, out the fork extend manifold and into the load handler manifold through port F1. Return oil flows through PVF, CV4, out port AT of the load handler manifold and to the reservoir. After a load handler function is no longer requested, CV4 works in conjunction with CV1 (in the main frame manifold) to maintain approximately 1.38 MPa (200 psi) in the circuit to obtain a fast response.

TSP 6000 Series

Crown 2005 PF15099-14 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits

SUCTION PRESSURE RETURN PILOT PRESSURE

Part of Load Handler Manifold from Main Frame Manifold

Fork Extend Manifold

to Reservoir

Figure 12882

Crown 2005 PF15099-15 Rev. 6/06

TSP 6000 Series

M2.0-1960-015 01 Rev. 6/06

131

HYDRAULIC SYSTEM Hydraulic Circuits Fork Retract Circuit PVF is the proportional valve that controls the fork extend function. When extending the forks, S1 coil is energized moving PVF spool to the left and when retracting the forks, S2 coil is energized moving PVF spool to the right (S1 is the top coil and S2 is the bottom coil). Access 7 controls PVF by varying the applied voltage to the coils. The more voltage applied to PVF coils, the more PVF spool moves which permits more oil to flow to the forks.

dler manifold and to the reservoir. After a load handler function is no longer requested, CV4 works in conjunction with CV1 (in the main frame manifold) to maintain approximately 1.38 MPa (200 psi) in the circuit to obtain a fast response.

Two valves in the load handler manifold control the pressure setting for the fork extend circuit, PVLH and PR2. When fork extend only is requested, the valve pressure settings are the same so the valves perform the same function. However, when more than one load handler function is requested, pressure settings may be different. For example, if auxiliary lift and fork extend are selected, PVLH will be electronically adjusted by Access 7 up to 24.1 MPa (3500 psi) to ensure adequate pressure for lift, while PR2 is factory set to limit maximum pressure to 9.7 MPa (1400 psi) to ensure proper pressure for fork extend. When an operator requests fork retract, Access 7 energizes PVF S2 coil shifting the valve spool in proportion to operator’s request. Access 7 also energizes PVLH coil adjusting the pressure setting to 9.7 MPa (1400 psi). Oil flows from the main frame manifold into port AP of the load handler manifold and to PVLH. PVLH pilot line senses pressure and if pressure is greater than 9.7 MPa (1400 psi) will move PVLH’s spool and divert some of the flow to reservoir. Oil flows through PR2. Pilot pressure is delivered to the top of PR2. If pressure is greater than 9.7 MPa (1400 psi), pilot pressure will overcome spring force and gradually move PR1’s spool down restricting flow to PVF limiting pressure to 9.7 MPa (1400 psi). Oil flows through PVF, out port F1 and into the fork extend manifold. Oil flows through a pilot line to SPC2 unseating the single pilot check valve permitting a path for return flow from the forks. Oil flows through SPC1, through the flow divider control valve (restricted) FDC, out manifold ports C1 and C2 and into the rear of the forks. Pilot pressure is delivered to both flow divider restrictions and is sensed from pressure on opposite sides of the restrictions. If a pressure differential exists across the restrictions, pilot pressure will adjust the restrictions to equalize the pressure to each fork ensuring equal movement of the rams. Return oil flows from the front of the forks, through ports C3 and C4 of the fork extend manifold, through SPC2, out the fork extend manifold and into the load handler manifold through port F2. Return oil flows through PVF, CV4, out port AT of the load hanM2.0-1960-016 01 Rev. 6/06

132

TSP 6000 Series

Crown 2005 PF15099-16 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits

SUCTION PRESSURE RETURN PILOT PRESSURE

Part of Load Handler Manifold

Fork Extend Manifold

from Main Frame Manifold to Reservoir

Figure 12883

Crown 2005 PF15099-17 Rev. 6/06

TSP 6000 Series

M2.0-1960-017 01 Rev. 6/06

133

HYDRAULIC SYSTEM Hydraulic Circuits Pivot Right Circuit PVP is the proportional valve that controls the pivot function. When pivoting right, S1 coil is energized moving PVP spool to the left and when pivoting counterclockwise, S2 coil is energized moving PVP spool to the right (S1 is the top coil and S2 is the bottom coil). The hydraulic control module, Access 7 controls PVP by varying the applied voltage to the coils. The more voltage applied to PVP coils, the more PVP spool moves which permits more oil to flow to the pivot cylinders. Two valves in the load handler manifold control the pressure setting for the pivot circuit, PVLH and PR2. When pivot only is requested, the valve pressure settings are the same so the valves perform the same function. However, when more than one load handler function is requested, pressure settings may be different. For example, if auxiliary lift and pivot are selected, PVLH will be electronically adjusted by Access 7 up to 24.1 MPa (3500 psi) to ensure adequate pressure for lift, while PR2 is factory set to limit maximum pressure to 9.7 MPa (1400 psi) to ensure proper pressure for pivot.

When an operator requests right pivot, Access 7 energizes PVP S1 coil shifting the valve spool in proportion to operator’s request. Access 7 also energizes PVLH coil adjusting the pressure setting to 9.7 MPa (1400 psi). Oil flows from the main frame manifold into port AP of the load handler manifold to PVLH. PVLH pilot line senses the pressure and if pressure is greater than 9.7 MPa (1400 psi), will move PVLH’s spool and divert some of the flow to the reservoir. Oil flows through PR2. Pilot pressure is delivered to the top of PR2. If pressure is greater than 9.7 MPa (1400 psi), pilot pressure will overcome spring force and gradually move PR2’s spool down restricting flow to PVP limiting pressure to 9.7 MPa (1400 psi). Oil flows through PCP and PVP to CBV3. Pressure is diverted to CBV4 through a pilot line. Oil flows through CBV3, out port R2 of the load handler manifold and into the front right pivot cylinder causing the right pivot cylinder piston rod to retract. Pressurized oil is forced from the rear right cylinder into the rear left pivot cylinder causing the left piston rod to extend. Return oil flows from the left cylinder, into port R1 of the load handler manifold through CBV4’s upper pivot line shifting CBV4’s spool creating a path for return oil. Oil flows through CBV4, PVP, CV4, out port AT of the load handler manifold and to the reservoir. After a load handler function is no longer requested, CV4 works in conjunction with CV1 (in the main frame manifold) to maintain approximately 1.38 MPa (200 psi) in the circuit to obtain a fast response. Pilot pressure is delivered to both sides of PCP and is sensed from pressure across PVP. If PVP is not fully opened then a pressure differential will exist across PVP. If pilot pressure sensed before PVP exceeds PCP’s spring force and the pilot pressure sensed at the load sense port of PVP, then PCP spool will shift right slowing flow and equalizing the pressure across PCP. This permits full pressure compensation of the pivot circuit flow. With the same operator command to PVP, the same flow will be delivered out port R2 regardless of load weight or pressure. It also provides for a smooth stop and start by preventing a sudden spike or drop in pressure should the operator suddenly stop and start pivoting.

M2.0-1960-018 01 Rev. 6/06

134

TSP 6000 Series

Crown 2005 PF15099-18 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits

SUCTION PRESSURE RETURN PILOT PRESSURE

Part of Load Handler Manifold from Main Frame Manifold

to Reservoir

Figure 12884-01

Crown 2005 PF15099-19 Rev. 6/06

TSP 6000 Series

M2.0-1960-019 01 Rev. 6/06

135

HYDRAULIC SYSTEM Hydraulic Circuits Pivot Left Circuit PVP is the proportional valve that controls the pivot function. When pivoting left, S1 coil is energized moving PVP spool to the left and when pivoting counterclockwise, S2 coil is energized moving PVP spool to the right (S1 is the top coil and S2 is the bottom coil). The hydraulic control module, Access 7 controls PVP by varying the applied voltage to the coils. The more voltage applied to PVP coils, the more PVP spool moves which permits more oil to flow to the pivot cylinders. Two valves in the load handler manifold control the pressure setting for the pivot circuit, PVLH and PR2. When pivot only is requested, the valve pressure settings are the same so the valves perform the same function. However, when more than one load handler function is requested, pressure settings may be different. For example, if auxiliary lift and pivot are selected, PVLH will be electronically adjusted by Access 7 up to 24.1 MPa (3500 psi) to ensure adequate pressure for lift, while PR2 is factory set to limit maximum pressure to 9.7 MPa (1400 psi) to ensure proper pressure for pivot.

1.38 MPa (200 psi) in the circuit to obtain a fast response. Pilot pressure is delivered to both sides of PCP and is sensed from pressure across PVP. If PVP is not fully opened then a pressure differential will exist across PVP. If pilot pressure sensed before PVP exceeds PCP’s spring force and the pilot pressure sensed at the load sense port of PVP, then PCP spool will shift right slowing flow and equalizing the pressure across PCP. This permits full pressure compensation of the pivot circuit flow. With the same operator command to PVP, the same flow will be delivered out port R1 regardless of load weight or pressure. It also provides for a smooth stop and start by preventing a sudden spike or drop in pressure should the operator suddenly stop and start pivoting.

When an operator requests left pivot, Access 7 energizes PVP S2 coil shifting the valve spool in proportion to operator’s request. Access 7 also energizes PVLH coil adjusting the pressure setting to 9.7 MPa (1400 psi). Oil flows from the main frame manifold into port AP of the load handler manifold to PVLH. PVLH pilot line senses the pressure and if pressure is greater than 9.7 MPa (1400 psi), will move PVLH’s spool and divert some of the flow to the reservoir. Oil flows through PR2. Pilot pressure is delivered to the top of PR2. If pressure is greater than 9.7 MPa (1400 psi), pilot pressure will overcome spring force and gradually move PR2’s spool down restricting flow to PVP limiting pressure to 9.7 MPa (1400 psi). Oil flows through PCP and PVP to CBV4. Pressure is diverted to CBV3 through a pilot line. Oil flows through CBV4, out port R1 of the load handler manifold and into the front left pivot cylinder causing the left pivot cylinder piston rod to retract. Pressurized oil is forced from the rear left cylinder into the rear right pivot cylinder causing the right piston rod to extend. Return oil flows from the right cylinder, into port R2 of the load handler manifold through CBV3’s upper pivot line shifting CBV3’s spool creating a path for return oil. Oil flows through CBV3, PVP, CV4, out port AT of the load handler manifold and to the reservoir. After a load handler function is no longer requested, CV4 works in conjunction with CV1 (in the main frame manifold) to maintain approximately

M2.0-1960-020 01 Rev. 6/06

136

TSP 6000 Series

Crown 2005 PF15099-20 Rev. 6/06

HYDRAULIC SYSTEM Hydraulic Circuits

SUCTION PRESSURE RETURN PILOT PRESSURE

Part of Load Handler Manifold from Main Frame Manifold

to Reservoir

Figure 12885-01

Crown 2005 PF15099-21 Rev. 6/06

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HYDRAULIC SYSTEM Hydraulic Schematic Symbols

Hydraulic Schematic Symbols VENTED RESERVOIR with lines above fluid level

ELECTRIC MOTOR unidirectional single speed

VENTED RESERVOIR with lines below fluid level ELECTRIC MOTOR unidirectional variable speed

FILTER or STRAINER

HYDRAULIC LINE with full flow (plumbing - may be tubing, hose, or flow passage in manifold

PILOT or DRAIN LINE limited flow

HYDRAULIC PUMP fixed displacement unidirectional

HYDRAULIC MOTOR bi-directional

LINES CROSSING

GAUGE pressure

LINES CONNECTED

QUICK DISCONNECT (disconnected)

GAUGE temperature

PLUGGED PORT (test port) ACCUMULATOR gas charged diaphragm type FLOW METER Figure 3559-03

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HYDRAULIC SYSTEM Hydraulic Schematic Symbols

PRESSURE SWITCH

ACTUATOR MANUAL

CYLINDER double acting unequal area

CYLINDER double acting equal area (steer) (double end)

SPRING (bias to normal de-energized position)

SOLENOID single coil or winding

CYLINDER single acting spring returned (rod end vented) HYDRAULIC PILOT OPERATED CYLINDER single acting ram type SOLENOID pilot operated

CYLINDER single acting with cushion SOLENOID DUAL

COMPONENT ENCLOSURE manifold block SOLENOID PROPORTIONAL

ACTUATOR MANUAL LEVER

VALVE PILOT CHECK (pilot to open) Figure 3560-03

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HYDRAULIC SYSTEM Hydraulic Schematic Symbols

ORIFICE THROTTLE fixed

VALVE SHUTTLE

ORIFICE THROTTLE adjustable

FLOW CONTROL PRESSURE COMPENSATED fixed

FLOW CONTROL PRESSURE COMPENSATED fixed with reverse flow bypass

FUSE VELOCITY

VALVE SINGLE COUNTERBALANCE in manifold

FLOW DIVIDER/COMBINER

BYPASS FLOW CONTROL regulated flow pressure compensated

VALVE RELIEF fixed setting

VALVE MANUAL SHUTOFF

TORQUE GENERATOR

VALVE RELIEF adjustable

STEER UNIT hydrostatic

VALVE CHECK

Figure 3561-03

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HYDRAULIC SYSTEM Hydraulic Schematic Symbols

VALVE 2 way 2 position

VALVE 3 way 2 position spring bias, solenoid control

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

VALVE 4 way 2 position

VALVE 4 way 3 position

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

VALVE 4 way infinite positions

Figure 3562-03

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HYDRAULIC SYSTEM Hydraulic Pump

Hydraulic Pump Before replacing the hydraulic pump, relieve hydraulic system pressure by following the procedure listed under Hydraulic in the Control of Hazardous Energy section of this manual.

Pump Replacement Refer to Figure 20782 1. Remove oil from reservoir until it is approximately 588 mm (24 in) from the top. 2. Disconnect hose (2) from pump. 3. Seal hose (2) to prevent contamination. 4. Seal breather on reservoir to reduce oil loss when suction hose (5) is removed. 5. Loosen clamp (3) from inlet (4) and remove suction hose (5). 6. Seal suction hose (5) to prevent contamination. 7. Secure motor and pump assembly with hoist and strap. 8. Remove motor mounting screws from mounting bracket. 9. Raise motor and pump assembly until there is clearance for the pump to be removed. 10. Remove screws (6). 11. Remove pump (1) exactly in line to avoid damage to the shafts or coupler. 12. Remove adapter flange (7) and inlet (4) from pump. 13. Replace any damaged or worn o-rings (8). Figure 20782

14. Attach adapter flange (7) and inlet (4) to new pump.

15. Lubricate coupler (9) with spline grease.

Attach strap with hooks or a two chain sling to mounting bracket sling holes

16. Install motor and pump assembly to mounting bracket. 17. Check components and hoses for contaminates. 18. Connect hose (2) to the adapter flange (7). 19. Connect hose (5) to the inlet (4). 20. Open breather on reservoir to assure proper oil flow to pump.

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HYDRAULIC SYSTEM Hydraulic Pump Initial Start Up Procedure •

Run pump at normal speed for a period of 10 minutes at minimum pressure, that is, with the hydraulic system unloaded.

•

If pump operating pressure can be directly controlled, ensure that the pressure is progressively increased up to full working requirements over the first hour of operation. In circumstances where the pressure cannot be directly controlled the same effect can be obtained by progressively increasing the work load on the machine over the same period of time.

•

During this period make frequent checks of the pump casing temperature, or the oil temperature, if a temperature gauge is included in the system. The temperature should not exceed that experienced under normal working conditions. If the temperature does rise excessively then it is possible that the pump is defective. If no fault is found then further period of running at low pressure is required.

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HYDRAULIC SYSTEM Manifold

Manifold

Proportional Valves Refer to section M4.3 for proportional valve calibration.

Relief Valve (RV1) The lift circuit is protected from excessive oil pressure by RV1 which is located on the main frame manifold. See Figure 20783. If pressure within the circuit exceeds the relief valve preset level, the valve will open and relieve pressure by directing oil to the reservoir, thus maintaining a maximum pressure limit for the circuit. A fully charged battery should be installed in the truck and all truck calibration and feature configuration should be completed before attempting any measurements or adjustments. To adjust RV1: 1. Connect a 0 to 35 MPa (0 to 5000 psi) pressure gauge to the test port of the main frame manifold. Insert thermometer in hydraulic oil. 2. Raise platform. Hold control in full lift position while reading gauge. Pressure reading must be taken while passing full flow over relief valve with pump operating. Pressure range is 24.8 MPa (3600 psi) at standard operating temperature. 3. If relief valve setting is not within required range, loosen jam nut on RV1 and adjust valve. 4. Tighten jam nut when adjustment is correct and recheck pressure setting. Readjust if necessary.

Figure 20783

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Test Port

Power Unit

TSP 6000 Series

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HYDRAULIC SYSTEM Manifold Manifold Block O-Ring Replacement 1. Locate main frame manifold on the left side of main frame and the load handler manifold in the top of the load handler assembly. 2. Open manual lowering valve (MVL) on main frame manifold to relieve system pressure.

WARNING AVOID HIGH PRESSURE FLUIDS - Escaping fluid under high pressure can penetrate the skin causing serious injury. • Relieve pressure before disconnecting hydraulic lines. • Tighten all connections before applying pressure.

•

Keep hands and body away from pin holes which eject fluids under high pressure. • Use a piece of cardboard or paper to search for leaks. Do not use your hand. Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain and serious damage may occur. Medical attention should be sought immediately by a specialist who has had experience with this type of injury.

function properly, discard valve and replace with new valve. 9. Remove top o-ring (cap) from each valve, cover threads on valve with sleeve or tape to prevent damage to replacement o-ring and carefully replace top o-ring. The top o-ring (cap) will be the closest to the outside surface of the manifold block after the valve is installed in manifold block. Visually inspect all other o-rings and back-up rings, replace as required. 10. Install each valve into manifold block by hand until snug. 11. Refer to section 02.4 for valve placement and Chart 1 for torque values of valves. Torque each valve to the value given. If using a crows foot or other extension, position it at 90° to torque wrench handle to keep torque value the same as torque wrench setting. Seal kits are available to replace all o-rings on each cartridge type valve. Refer to section 02.4 for seal kit part numbers. Chart 1 lists torque values for all cartridge type valves installed in the main frame and load handler manifolds. Refer to chart whenever installing a replacement cartridge valve(s).

3. Remove all hydraulic hoses and lines from manifold blocks, cap lines and hoses with plastic plugs to avoid oil leakage and contamination. Catch any oil that may be spilled. 4. Loosen accessible cartridge valves while the manifold blocks are still in the truck, do not remove any valves at this time. 5. Remove manifold blocks from truck and place on a clean piece of cardboard in a clean area to avoid contamination while disassembling. 6. Remove all valves from manifold blocks and place on a clean piece of cardboard. During entire disassembly, replacement of o-rings, putting valves back into manifolds and proper torque of valves, it is extremely important to keep work surfaces and parts as clean as possible to avoid contamination. 7. Do not remove any orifices or SAE plugs from manifold blocks. 8. Make a visual inspection of valves and valve cavities for any signs of contamination. Check operation of valve mechanisms for sticking or rough operation. If any valves are contaminated or do not Crown 2005 PF15106-2 Rev. 1/09

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HYDRAULIC SYSTEM Manifold

CHART 1 Main Frame Manifold Item

Valve Part Number

Cartridge Torque

Coil Nut Torque

ft lb

Valve Part Number

Item

Cartridge Torque

Coil Nut Torque

ft lb

RV1

117913-003

PVMR

135800

SP1

135724-001

PVML

135800

PCA

139437

PCML

135271

PCBy

139436

SVML

135723-001

CV1

117380-002

MVL

135722

CV2

123255-003

Load Handler Manifold Item

Valve Part Number

Cartridge Torque

Coil Nut Torque

ft lb

Item

Valve Part Number

Cartridge Torque

Coil Nut Torque

ft lb

PVLH

135727

CBV1

135725

PCAR

135732

CBV2

135725

PVAR

135724-002

CBV3

135718

PCAL

135731

CBV4

135718

PVAL

135724-002

CV3

117380-002

PCT

135732

CV4

114816-003

PVT

135729-002

PR1

135726-001

PVF

135730

PR2

135726-002

PCP

135732

RV2

138361

PVP

135728

RV3

138361

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HYDRAULIC SYSTEM Hydraulic Motor

Hydraulic Motor

Tools and Materials Required for Servicing

Preparation Before Disassembly

•

Clean, petroleum-based solvent

Before you disassemble the hydraulic motor or any of its components, read this entire maintenance section. It provides important information on parts and procedures you will need to know to service the hydraulic motor. Refer to the tool list for tools and other items required to service the hydraulic motor and have them available.

•

Emery paper

•

Vise with soft jaws

•

Air pressure source

•

Arbor press

•

Thoroughly clean off all outside dirt, especially from around fittings and hose connections, before disconnecting and removing the hydraulic motor.

•

Screwdriver

•

Masking tape

•

Remove rust or corrosion from coupling shaft.

•

Breaker bar

•

Remove coupling shaft connections and hose fittings and immediately plug port holes and fluid lines.

•

Torque wrench - Nm (ft lb)

•

Sockets: 1/2 or 9/16 inch thin wall, 1 inch

•

Allen sockets: 3/16, 3/8 inch

•

Adjustable crescent wrench or hose fitting wrenches

•

SAE 10W40 SE or SF oil

•

Special bearing mandrel (refer to Figure 21256)

•

Feeler gage 0.13 mm (0.005 in)

•

Blind hole bearing puller for 26.9 mm (1.06 in) and 41.1 mm (1.62 in) diameter bearing/bushing

•

Clean corrosion resistant grease. Recommended grease is E/M Lubricant #K-70M, Crown #107334

•

Remove the hydraulic motor from truck, drain it of fluid and take to a clean work surface.

•

Clean and dry the unit before you start to disassemble the unit.

•

As you disassemble the unit, clean all parts, except seals, in clean petroleum-based solvent and blow them dry.

WARNING Be extremely careful when using any solvent. Even a small explosion or fire could cause injury or death. Always wear eye protection and be sure to comply with OSHA or other maximum air pressure requirements.

NOTE The available service seal kits include the recommended grease as a grease pack.

CAUTION Never steam or high pressure wash hydraulic components. Do not force or abuse closely fitted parts. Keep parts separate to avoid nicks and burrs. Discard all seals and seal rings as they are removed from the unit. Replace all seals, seal rings and any damaged parts with approved service parts.

Crown 2005 PF15110-1 Rev 1/09

CAUTION Mixing greases that have different bases can be detrimental to bearing life.

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HYDRAULIC SYSTEM Hydraulic Motor

Knurl

Figure 21256

M2.6-1960-002 01 Rev. 1/09

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TSP 6000 Series

Crown 2005 PF15110-2 Rev 1/09

HYDRAULIC SYSTEM Hydraulic Motor Disassembly and Inspection Refer to Figure 21257.

Matched Set

Figure 21257

1. Place hydraulic motor in soft jawed vice, with coupling shaft (11) pointed down and the vise jaws clamping firmly on the sides of the housing (18) mounting flange or port bosses.

2. Scribe an alignment mark down and across the hydraulic motor components from end cover (2) to housing (18) to facilitate reassembly orientation where required. Refer to Figure 12924.

WARNING If the hydraulic motor is not firmly held in the vise, it could be dislodged during the service procedures, causing injury.

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HYDRAULIC SYSTEM Hydraulic Motor 4. Inspect bolts for damaged threads, or sealing rings, under the bolt head. Refer to Figure 12926.

Figure 12924

3. Remove the six special ring head bolts, refer to Figure 12925.

Figure 12926

5. Remove end cover assembly (2) and seal ring (4). Discard seal ring (4). Refer to Figure 12927.

Figure 12925 Figure 12927

6. Thoroughly wash end cover (2) in proper solvent and blow dry. Inspect end cover for cracks and the bolt head recesses for good bolt head sealing surfaces. Replace end cover if necessary.

NOTE A polished pattern (not scratches) on cover from rotation of the commutator (5) is normal. Discoloration would indicate excess fluid temperature, thermal shock or excessive speed and require system investigation for cause and close inspection of end cover, commutator, manifold and rotor set.

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Crown 2005 PF15110-4 Rev 1/09

HYDRAULIC SYSTEM Hydraulic Motor 7. Remove commutator ring (5). Inspect commutator ring for cracks or burrs. Refer to Figure 12928.

9. Remove manifold (6) and inspect for cracks, surface scoring, brinelling or spalling. Replace manifold if any of these conditions exist. A polished pattern on the ground surfaces from commutator or rotor rotation is normal. Remove and discard the seal rings (4) that are on both sides of manifold. Refer to Figure 12931.

Figure 12928

8. Remove commutator (5) and seal ring (3). Remove seal ring from commutator, using an air hose to blow air into ring groove until seal is lifted out and discard seal ring (3). Inspect commutator for cracks, burrs, wear, scoring, spalling or brinelling. If any of these conditions exist, replace commutator and commutator ring as a matched set. Refer to Figure 12929 and 12930.

Figure 12931

NOTE The manifold is constructed of plates bonded together to form an integral component not subject to further disassembly for service. Compare configuration of both sides of the manifold to ensure that same surface is reassembled against the rotor set.

Figure 12929

Figure 12930 Crown 2005 PF15110-5 Rev 1/09

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HYDRAULIC SYSTEM Hydraulic Motor 10. Remove rotor set (7) and wear plate (8) together to retain the rotor set in its assembled form, maintaining the same rotor vane (7c) to stator (7b) contact surfaces. Refer to Figure 12932. The drive link (9) may come away from the coupling shaft (11) with the rotor set and wear plate. You may have to shift the rotor set on the wear plate to work the drive link out of the rotor (7a) and wear plate, refer to Figure 12933. Inspect the rotor set in its assembled form for nicks, scoring or spalling on any surface and for broken or worn splines. If the rotor set component requires replacement, the complete rotor set must be replaced as it is a matched set. Inspect seal ring (4) that is between the rotor set and wear plate.

at assembly will ensure maximum wear life and performance of rotor set and hydraulic motor.

NOTE A polished pattern on the wear plate from rotor rotation is normal. 11. Place rotor set (7) and wear plate (8) on a flat surface and center rotor (7a) in stator (7b) such that two rotor lobes (180° apart) and a roller vane (7c) centerline are on the same stator centerline. Check the rotor lobe to roller vane clearance with a feeler gage at this common centerline. If there is more than 0.13 mm (0.005 in) of clearance, replace rotor set. Refer to Figure 12934.

Figure 12932 Figure 12934

12. Remove drive link (9) from coupling shaft (11) if it was not removed with rotor set and wear plate. Inspect drive link for cracks and worn or damaged splines. No perceptible backlash (play) should be noted between mating spline parts. Remove and discard seal ring (4) from housing (18). Refer to Figure 12935.

Figure 12933

NOTE The rotor set (7) components may become disassembled during service procedures. Marking the surface of the rotor and stator that is facing UP with etching ink or grease pencil before removal from hydraulic motor will ensure correct reassembly of rotor into stator and rotor set into hydraulic motor. Marking all rotor components and mating spline components for exact repositioning

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TSP 6000 Series

Figure 12935

Crown 2005 PF15110-6 Rev 1/09

HYDRAULIC SYSTEM Hydraulic Motor 13. Check exposed portion of coupling shaft (11) to be sure you have removed all signs of rust and corrosion which might prevent its withdrawal through the seal and bearing. Crocus cloth or fine emery paper may be used. Refer to Figure 12936. Remove the key.

Inspection Areas

Figure 12938

NOTE Figure 12936

14. Remove coupling shaft (11) by pushing on the output end of shaft, refer to Figure 12937. Inspect coupling shaft bearing and seal surfaces for spalling, nicks, grooves, severe wear or corrosion and discoloration. Inspect for damaged or worn internal and external splines or keyway. Replace coupling shaft if any of these conditions exist. Refer to Figure 12938 for critical inspection areas.

Minor shaft wear in seal area is permissible. If wear exceeds 0.51 mm (0.020 in) diametrically, replace coupling shaft. A slight polish is permissible in the shaft bearing areas. Anything more would require coupling shaft replacement. 15. Remove and discard seal ring (4) from housing (18). 16. Remove thrust bearing (13) and thrust washer (14) from the unit. Inspect for wear, brinelling, corrosion and a full complement of retained rollers. Refer to Figure 12939.

Figure 12937 Figure 12939

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HYDRAULIC SYSTEM Hydraulic Motor 17. Remove seal (15) and back up ring (17) from housing (18) and back up washer (16), discard both. Refer to Figure 12940.

19. Inspect housing (18) assembly for cracks. Check the machined surfaces for nicks, burrs, brinelling or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assembly. Refer to Figure 12942.

Figure 12940

18. Remove housing (18) from vise, invert it and remove and discard seal (20). A blind hole bearing or seal puller is required. Refer to Figure 12941.

Figure 12942

20. If the housing assembly (18) has passed inspection to this point, inspect the housing bearings/ bushings (19) and (12). If the unit is equipped with roller bearings, make sure they are captured in the housing cavity by the two thrust washers (13) and thrust bearing (14). The bearing rollers must be firmly retained in the bearing cages, but must rotate and orbit freely. All rollers and thrust washers must be free of brinelling and corrosion, refer to Figure 12943.

Figure 12941

Figure 12943

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Crown 2005 PF15110-8 Rev 1/09

HYDRAULIC SYSTEM Hydraulic Motor 21. The hydraulic motor bushing (19) or (12) to coupling shaft diametrical clearance must not exceed 0.025 mm (0.010 in). A bearing, bushing or thrust washer that does not pass inspection must be replaced. If the housing has passed this inspection the disassembly of the hydraulic motor is completed. Refer to Figure 12944.

22. If the bearings, bushings or thrust washers must be replaced use a suitable size bearing puller to remove bearing and bushing (19) and (12) from housing (18) without damaging the housing. Remove thrust washers (14) and thrust bearing (13) if they were previously retained in the housing by bearing and bushing (12). Refer to Figure 12946 and 12947.

Figure 12944 Figure 12946

NOTE The depth or location of bearing/bushing (12) in relation to the housing wear plate surface and the depth or location of bearing/bushing (19) in relation to the beginning of bearing/bushing counterbore should be measured and noted before removing the bearings/bushings. This will facilitate the correct reassembly if new bearings/bushings are required. Refer to Figure 12945.

Figure 12947

Figure 12945

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155

HYDRAULIC SYSTEM Hydraulic Motor Reassembly Replace all seals and seal rings with new ones each time you reassemble the hydraulic motor. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly.

NOTE Individual seals and seal rings as well as a complete seal kit are available.

NOTE

23. If housing (18) bearing components were removed for replacement, thoroughly coat and pack a new outer bearing/bushing (19) with clean corrosion resistant grease. Recommended grease is E/M Lubricant #K-70M, Crown No. 107334. Press the new bearing/bushing into the counterbore at the mounting flange end of the housing using a bearing mandrel, refer to Figure 12923. This bearing mandrel will seat the bearing and bushing (19) into the housing to a required depth of 3.84 - 4.09 mm (0.151 - 0.161 in.) from the end of the bearing counterbore. Refer to Figure 12948.

Unless otherwise indicated, do not oil or grease parts before assembly. Wash all parts in clean petroleum-based solvents before assembly. Blow them dry with compressed air. Remove any paint chips from mating surfaces of the end cover, commutator set, manifold rotor set, wear plate and housing and from port and sealing areas.

Figure 12948

NOTE Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing/bushing is not cocked when pressing a bearing/bushing into the housing.

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TSP 6000 Series

Crown 2005 PF15110-10 Rev 1/09

HYDRAULIC SYSTEM Hydraulic Motor CAUTION If the bearing mandrel specified is not available and alternate methods are used to press in bearing and bushing (12) and (19), the bearing and bushing depths specified must be achieved to insure adequate bearing support and correct relationship to adjacent components when assembled. Refer to Figure 12949.

25. Apply a small amount of clean grease to a new dirt and water seal (20) and press it into the housing (18) outer bearing counterbore. It must be pressed in until its flange is flush against the housing. Refer to Figure 12952.

Figure 12952

Figure 12949

26. Place housing (18) assembly into a soft jawed vise with the coupling shaft bore down, clamping against the mounting flange. Refer to Figure 12953.

CAUTION Because the bearing and bushings (12) and (19) have a press fit into housing they must be discarded when removed. They must not be reused. 24. The hydraulic motor inner housing bearing/bushing (12) can now be pressed into its counterbore in housing (18) flush to 0.76 mm (0.03 in) below the housing wear plate contact face. Use the opposite end of the bearing mandrel that was used to press in the outer bearing/bushing (19). Refer to Figure 12950. Figure 12953

Figure 12950

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HYDRAULIC SYSTEM Hydraulic Motor 27. Assemble a new backup ring (17), new backup washer (16) and new seal (15) with the seal lip facing toward the hydraulic motor, into their respective counterbores in housing (18). Refer to Figures 12954 and 21274.

28. Assemble thrust washer (14) then thrust bearing (13) that was removed from the hydraulic motor. Refer to Figure 12955.

Figure 12955

NOTE

Figure 12954

The hydraulic motor requires one thrust washer (14) with thrust bearing (13). The coupling shaft will be seated directly against the thrust bearing.

Figure 21274 1

Thrust Washers

Thrust Bearing

Seal

Backup Washer

Housing

Backup Ring

Shaft

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TSP 6000 Series

Crown 2005 PF15110-12 Rev 1/09

HYDRAULIC SYSTEM Hydraulic Motor 29. Apply masking tape around splines or keyway on shaft (11) to prevent damage to seal. Refer to Figure 12956.

NOTE The coupling shaft (11) will be flush or just below the housing wear plate surface when properly seated. The coupling shaft must rotate smoothly on the thrust bearing package. Refer to Figure 12958.

Figure 12956

30. Be sure that a generous amount of clean corrosion resistant grease has been applied to the lower (outer) housing bearing and bushing (19). Install the coupling shaft (11) into housing (18), seating it against the thrust bearing (14). Refer to Figure 12957.

Figure 12958

31. Apply a small amount of clean grease to a new seal ring (4) and insert it into the housing (18) seal ring groove. Refer to Figure 12959.

Figure 12957

Figure 12959

NOTE

CAUTION The outer bearing (19) is not lubricated by the system's hydraulic fluid. Be sure it is thoroughly packed with the recommended grease (107334).

Crown 2005 PF15110-13 Rev 1/09

One or two alignment studs screwed finger tight into housing (18) bolt holes, approximately 180° apart, will facilitate the assembly and alignment of components as required in the following procedures. The studs can be made by cutting off the heads of either 3/8-24 UNF 2A or 5/16-24 UNF 2A bolts as required that are over 12.7 mm (0.5 in) longer than the bolts (1) used in the hydraulic motor.

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HYDRAULIC SYSTEM Hydraulic Motor 32. Install drive link (9) the long splined end down into the coupling shaft (11) and engage the drive link splines into mesh with the coupling shaft splines. Refer to Figure 12960.

34. Apply a small amount of clean grease to a new seal ring (4) and assemble it into the seal ring groove on the wear plate side of the rotor set stator (7b). Refer to Figure 12962.

Figure 12960

NOTE Use the alignment marks put on the coupling shaft and drive link before disassembly to assemble the drive link splines in their original position in the mating coupling shaft splines.

Figure 12962

35. Install the assembled rotor set (7) onto wear plate (8) with rotor (7a) counterbore and seal ring side down. Mesh splines with the drive link splines. Refer to Figure 12963.

33. Assemble wear plate (8) over the drive link (9) and alignment studs onto the housing (18). Refer to Figure 12961.

Figure 12963

NOTE Figure 12961

It may be necessary to turn one alignment stud out of the housing (18) temporarily to assemble rotor set (7) or manifold (6) over the drive link.

NOTE The rotor set rotor counterbore side must be down against wear plate for drive link clearance and to maintain the original rotor-drive link spline contact. A rotor set without a counterbore and that was not etched before disassembly can be reinstalled using the drive link spline pattern on the rotor splines, if apparent, to determine which side was down. The rotor set seal ring groove faces toward the wear plate (8). M2.6-1960-014 01 Rev. 1/09

160

TSP 6000 Series

Crown 2005 PF15110-14 Rev 1/09

HYDRAULIC SYSTEM Hydraulic Motor 36. Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (6). Refer to Figure 12964.

38. Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. Refer to Figure 12966.

Figure 12964

Figure 12966

39. Assemble the commutator ring (5) over alignment studs onto the manifold. Refer to Figure 12967.

NOTE The manifold (6) is made up of several plates bonded together permanently to form an integral component. The manifold surface that must contact the rotor set has its series of irregular shaped cavities on the largest circumference or circle around the inside diameter. The polished impression left on the manifold by the rotor set is another indication of which surface must contact the rotor set. 37. Assemble the manifold (6) over the alignment studs and drive link (9) and onto the rotor set. Be sure the correct manifold surface is against the rotor set. Refer to Figure 12965.

Figure 12967

Figure 12965

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HYDRAULIC SYSTEM Hydraulic Motor 40. Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (9) onto manifold (6) with seal ring side up. Refer to Figures 12968 and 12969.

Figure 12970

Figure 12968

Figure 12971 Figure 12969

41. Assemble a new seal ring (4) into end cover (2) and assemble end cover over alignment studs and onto the commutator set, refer to Figures 12970 and 12971. Be sure the cover holes are aligned with the threaded holes in housing (18). Refer to Figure 12972.

NOTE Use the line you previously scribed on the cover to radially align the end cover into its original position.

Figure 12972

M2.6-1960-016 01 Rev. 1/09

162

TSP 6000 Series

Crown 2005 PF15110-16 Rev 1/09

HYDRAULIC SYSTEM Hydraulic Motor 42. Assemble the 6 bolts (1) and screw in finger tight. Remove and replace the two alignment studs with bolts after the other bolts are in place. Alternately and progressively tighten the bolts to pull the end cover and other components into place with a final torque of 30-35 Nm (22-26 ft lb) for the 5/16-24 threaded bolts. Refer to Figures 12973, 12974 and 12975.

Final Checks 1. Pressurize the hydraulic motor with 0.69 MPa (100 psi) dry air or nitrogen and submerge in solvent to check for external leaks. 2. Check hydraulic motor for rotation. Torque required to rotate coupling shaft should not be more than 68 Nm (50 ft lb). 3. Pressure port with A cast under it on housing (18) is for clockwise coupling shaft rotation as viewed from the output end of coupling shaft. Pressure port with B cast under it is for counterclockwise coupling shaft rotation. 4. Use test stand if available to check operation of the hydraulic motor.

Figure 12973

Figure 12974

Figure 12975

Crown 2005 PF15110-17 Rev 1/09

TSP 6000 Series

M2.6-1960-017 01 Rev. 1/09

163

HYDRAULIC SYSTEM Hydraulic Motor

Troubleshooting Chart Trouble Oil leakage

Cause

Remedy

Hose fittings loose, worn, or damaged.

Check and replace damaged fittings or orings. Torque to manufacturers specifications

Oil seal rings (4) deteriorated by excess Replace oil seal rings by disassembling unit. heat. Bolt (1) loose or its sealing area deterio- Loosed then tighten single bolt to torque rated by corrosion. specification. Replace bolt.

Significant loss of speed under load

Internal shaft seal (15) worn or damaged.

Replace seal. Disassembly of unit necessary.

Worn coupling shaft (11) and internal seal (15).

Replace coupling shaft and seal by disassembling unit.

Lack of sufficient oil supply.

Check for faulty relief valve and adjust or replace as required. Check for and repair worn pump. Check for and use correct oil for temperature of operation.

Low mechanical efficiency or undue high pressure required to operate unit\

High internal motor leakage.

Replace worn rotor set by disassembling unit.

Severely worn or damaged internal splines.

Replace rotor set, drive link, and coupling shaft by disassembling unit.

Excessive heat.

Locate excessive heat source (usually a restriction) in the system and correct the condition.

Line blockage.

Locate blockage source and repair or replace.

Internal interference.

Disassemble unit, identify and remedy cause and repair, replacing parts as necessary.

Lack of pumping pressure.

Check for and repair worn pump.

Excessive binding or loading in system Locate source and eliminate cause. external to hydraulic motor.

CAUTION If the hydraulic system fluid becomes overheated (in excess of 93.3 °C [200 °F]), seals in the system can shrink, harden or crack, thus losing their sealing ability.

M2.6-1960-018 01 Rev. 1/09

164

TSP 6000 Series

Crown 2005 PF15110-18 Rev 1/09

DRIVE UNIT

165

Notes:

166

DRIVE UNIT Drive Unit

Drive Unit The truck is equipped with a single drive unit mounted in the center of the power unit. Drive unit is a double gear reduction unit totally enclosed and drive unit is filled with oil with all the gears submerged in oil. Traction is supplied by an AC motor (M1) and truck braking is provided by an electric brake (BRK) mounted on top of the drive motor. The AC drive motor contains encoder ECR7 which monitors motor speed and position and temperature sensor (TS1). Also mounted externally on drive motor is a feedback splitter (FSB).

Drive Tire Replacement NOTE When installing a new drive tire the new tire must be lathe cut. Refer to lathe cutting instructions and tire dimensions in this section. 1. Move truck to a secure non-traffic maintenance area with a level floor. Lower platform and forks, and chock load wheels. 2. Open and remove power unit doors and turn drive tire so lug nuts are accessible for removal and disconnect battery.

Figure 20786 1

Securely block power unit corners

Wheel chock both load wheels

4. Remove center skirting to allow access to drive tire and lug nuts. 5. Remove steer wheel wire guidance bracket on trucks equipped with wire guidance option.

CAUTION If truck is equipped with wire guidance make sure when raising rear of the power unit the jack does not damage the steer wheel wire guidance bracket. 3. Using a hydraulic jack, raise the rear of the power unit so the drive tire just clears the floor. Place hardwood blocks under each corner of power unit. After blocks are in place and truck is secure, remove the jack. Refer to Control of Hazardous Energy Lockout/Tagout section for lifting and blocking instructions. Refer to Figure 20786.

6. Remove eight lug nuts and drive tire from drive unit. 7. Press existing tire off of hub. 8. Inspect hub for any damage and replace as needed. 9. Remove any paint that may be present on tapered lug seats or on inner hub face that contacts truck axle. 10. Verify replacement drive tire being installed is of the correct composition and size. The incorrect type of tire can affect maneuverability and braking requirements of the truck. Refer to Drive Wheel section for tire part number selection. 11. Press replacement tire onto hub. The outside of the hub must be pressed flush with the outside edge of the tire. 12. Install tire on truck and finger tighten lug nuts.

Crown 2005 PF15105-1 Rev. 12/09

TSP 6000 Series

M3.0-1960-001 03 Rev. 12/09

167

DRIVE UNIT Drive Unit 13. Torque lug nuts in numerical sequence per Figure 20787.

•

First torque sequence value 41 - 54 Nm (30 - 40 ft lb) to seat nuts

•

Second torque sequence value 122 - 136 Nm (90 - 100 ft lb)

•

Third torque sequence value 205 - 216 Nm (151 - 159 ft lb)

CAUTION Wear safety gloves and glasses while operating rotating machinery. Do not wear loose fitting clothing that could be caught and pulled into the machine. 1. Mount tire and hub assembly onto lathe chucking off the bearing inner race or the hub inside diameter. 2. Using outside diameter calipers as a measuring guide, trim wheel down to 38 mm ± 1.5 mm (15.0 in ± 0.060 in) in diameter. Approximately 6.3 mm (0.25 in) needs to be trimmed from tire. Refer to Figure 20788.

NOTE Do not try to remove full amount from tire in first cutting. Remove small amounts and measure frequently. 3. The outside tire diameter to be concentric to inside bearing diameter within 1.0 mm (0.040 in) total indicator run out.

Figure 20787

14. If truck is equipped with wire guidance reinstall steer wheel wire guidance bracket on truck. 15. Install rear skirting on truck. 16. Raise rear of power unit and remove blocking material from under truck and lower to floor. 17. Install power unit doors. 18. Verify truck is operational. 19. If truck is equipped with wire guidance verify calibration of wire guidance system.

Lathe Cutting The new drive wheel must be sized down to a diameter of 381 mm ± 1.5 mm (15.0 in ± 0.060 in) after the tire is pressed onto the hub.

NOTE

Figure 20788 1

Break sharp corners

Press flush

The tire can not be lathe cut before the hub is pressed in due to requirements for hub-bearing bore concentricity to the tire's outside diameter.

M3.0-1960-002 03 Rev. 12/09

168

TSP 6000 Series

Crown 2005 PF15105-2 Rev. 12/09

DRIVE UNIT Drive Unit Drive Unit Lubrication Drive unit capacity is 6.2 liters (6.55 quarts) of Mobilube1 SHC 75W-90 synthetic gear oil or equivalent. This gear oil can be used in all applications including freezer operations. Substitute gear oil must meet service grade rating of API GL-4 to preserve the drive unit's warranty. On new trucks the initial oil change should be at 250 hours of operation and then every 2500 hours of operation or 1 year which ever occurs first. To gain access to the drive unit, open power unit doors and remove rear skirt. It may be necessary to turn the steer wheel to gain access to the fill plug (1) and drain plug (2) and to remove the steer wheel wire guidance bracket if the truck has optional wire guidance.

5. Clean area around fill plug and remove fill plug (1) which is located at top of the drive unit. Refer to Figure 20789. 6. Fill with oil until it just starts running out of fill hole (6.2 liters [6.55 qt]). 7. Inspect fill plug seal and replace as needed. Install fill plug (1). Check for leaks. 8. Close drive unit doors and run operational check on truck. 9. Verify wire guidance calibration if truck is equipped with optional wire guidance.

Drive Unit Removal

The drain plug (2) is located on the bottom of drive unit. Refer to Figure 20789.

CAUTION If truck is equipped with wire guidance make sure when raising rear of the power unit the jack does not damage the steer wheel wire guidance bracket. 1. Raise rear of power unit so drive tire just clears the floor. Place hardwood blocks under each corner of power unit. After blocks are in place and truck is secure remove jack. Refer to Control of Hazardous Energy Lockout/Tagout section for lifting and blocking instructions. 2. Open and remove power unit doors to gain access to the drive unit. 3. Remove rear skirt from truck. 4. Remove steer wheel guidance bracket if truck is equipped with wire guidance. 5. Attach a lifting sling around the drive unit and apply some pressure on sling with lifting device.

Figure 20789

1. Turn steer wheel to gain access to the fill plug (1) and drain plug (2). 2. Disconnect battery and chock load wheels. 3. Remove drain plug (2). Collect oil and dispose of properly. 4. Once drive unit oil has been drained, inspect drain plug seal before reinstalling and replace seal as needed.

Crown 2005 PF15105-3 Rev. 12/09

TSP 6000 Series

M3.0-1960-003 03 Rev. 12/09

169

DRIVE UNIT Drive Unit 6. Remove six screws (1) that secure drive unit to drive unit mounting plate. Refer to Figure 20790.

Drive Motor Removal 1. Move truck to a secure non-traffic maintenance area with a level floor. Lower platform and forks, disconnect battery and chock load wheels. 2. Open power unit doors to gain access to drive motor. 3. Disconnect all wiring to drive motor and brake and label wires/connectors to aid in reinstalling drive motor and brake assembly. 4. Attach a lifting sling around motor and brake assembly. 5. Remove four mounting screws that secure motor and brake assembly to drive unit. 6. Using a lifting device remove motor and brake assembly from truck.

Drive Motor Installation Figure 20790

7. Using lifting device remove drive unit from truck.

Drive Unit Installation

1. Apply spline grease to drive motor shaft and drive unit spline. 2. Using a sling attached to replacement motor and brake assembly install with the use of a lifting device. 3. Secure drive motor and brake assembly with four screws.

1. Inspect bumpers on drive unit and replace as needed.

4. Torque screws to 43 Nm (32 ft lb).

2. Apply spline grease to drive unit spline and drive motor shaft. 3. Using a sling and lifting device move drive unit into place for mounting to drive unit mounting plate. 4. Install six mounting screws and torque to 43 Nm (32 ft lb).

5. Remove sling from motor brake assembly. 6. Reconnect all electrical connections to drive motor and brake assembly. 7. Close power unit doors and verify truck is operational.

5. Install wire guidance steer wheel bracket on trucks equipped with wire guidance. 6. Install rear skirt on truck. 7. Using a jack raise power unit and remove blocking material and lower truck to floor. 8. Verify oil level in drive unit. Add oil as needed. 9. Install power unit doors. 10. Verify drive unit is fully operational. 11. Verify wire guidance calibration on trucks equipped with this option.

M3.0-1960-004 03 Rev. 12/09

170

TSP 6000 Series

Crown 2005 PF15105-4 Rev. 12/09

ELECTRICAL SYSTEM

171

Notes:

172

ELECTRICAL SYSTEM ACCESS 123®

ACCESS 123®

Power Cable Connections

The ACCESS 1 module, commonly referred to as the display, is the interface between the operator or service technician and the truck electronic system.

WARNING Never key ON truck with any control connectors disconnected. In addition, never remove or connect any control connectors while truck is keyed ON.

CAUTION

CAUTION Due to capacitance voltage present on the motor control panel, whenever performing maintenance which may permit contact with the bus bars and associated power cables, discharge capacitor on the traction control panel by placing a minimum 100 Ω, 2 W resistor (062033-030) between positive (+) and negative (-) of capacitor for 3 or more seconds.

Software Package Version Level

After changing any module or updating software, check truck setups and re-calibrate if required.

When a Malfunction Occurs 1. Go to the display and access the Level 2: Field Service Mode as follows. Note: Your monitoring system can be accessed at three levels of authorization: –

Level 1: Operator Mode

–

Level 2: Field Service Mode (Full Truck Operation)

–

Level 3: Analyzer/Test Mode (No Truck Operation)

To find the current software package version level that is installed in the truck:

•

Go to the Utilities menu.

•

Scroll down to U1 Part Numbers.

•

In the menu selections choose U1.9 Vehicle.

The software package part number will be displayed, the last dash number will be the current software package version that is installed in the truck.

This guide deals with the Level 2 and Level 3. For information on Level 1 see the Operators Manual. 2. Turn the key OFF. Hold down the up arrow and turn the key back ON. 3. Enter your four digit access code using the up and down arrows to find the correct number for the first digit. Press the enter key to move to the next digit. When all four digits have been entered press the enter key again to access the main menu. 4. Press the down arrow to move down the main menu to the Event Codes menu and press the enter key to enter the menu. 5. Press the enter key to select L1 Event History for list of logged three digit event codes. 6. Check the event code section for a description of the possible problem, to identify the components affected and corrective actions to be taken.

Crown 2006 PF15239-1 Rev. 1/09

TSP 6000 Series

M4.3-1960-001 02 Rev. 1/09

173

ELECTRICAL SYSTEM ACCESS 123®

Hydraulic Valves Position Sensors • Pivot • Traverse • Aux Lift Height

Left Hand Sensors Right Hand Sensors

CAN BUS

Platform Sensors • Foot Pedals • Gates • Chain • Main Lift Height • Seat Position Seat Release Solenoid

Platform Power Unit Traction Motor Travel Alarm

Main Hoist Hydraulic Valves Hydraulic Pump Motor Sensors • Motor Speed • Height Cable • Tension Switch

Motor Sensor E.D. Contactor

Steer Motor Traction Brake Main Hoist P.C. Valve Sensors • Steer Wheel Position • Current Sensor • Rail Guide Switches

Wire Guide Sensor Bars EAC Sensors

Figure 12573-02

M4.3-1960-002 02 Rev. 1/09

174

TSP 6000 Series

Crown 2006 PF15239-2 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123®

DCM - ACCESS 1 Display Control Module HCM - ACCESS 2 Hydraulic Control Module TCM - ACCESS 3 Traction Control Module VCM - ACCESS 4 Vehicle Control Module SCM - ACCESS 5 Steering Control Module GCM - ACCESS 6 Guidance Control Module ACM - ACCESS 7 Accessory Control Module OCM - ACCESS 8 Operator Control Module

ACCESS 1 Display Module (DCM)

Power ON Indicator Display Screen

Capacity Data Monitor

Service Required Indicator

Battery Discharge Indicator

Enter or Return Key Used to navigate in and out of menus and to accept inputs.

Navigation Keys • Up Arrow • Down Arrow Used to scroll through menus. Figure 12575-02

Crown 2006 PF15239-3 Rev. 1/09

TSP 6000 Series

M4.3-1960-003 02 Rev. 1/09

175

ELECTRICAL SYSTEM ACCESS 123® Main Menu

Enter password using the up and down arrow keys and enter key to select each number or letter.

FIELD SERVICE MODE: Menu Selections: Analyzer (see page -005) Calibration (see page -028 Features (see page -050) Hour Meters (see page -064) Event Codes (see page -065) Performance (see page -066) Utilities (see page -080)

Figure 13920-02

M4.3-1960-004 02 Rev. 1/09

176

TSP 6000 Series

Crown 2006 PF15239-4 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Analyzer Menus

Analyzer Menu Selections: A1 Status A2 Inputs (see page -006) A3 Outputs (see page -013) A4 Test Outputs (2 button mode) (see page -022) A99 Escape returns back to FIELD SERVICE MODE Menu.

A1.1 A1.2 A1.3 A1.4 A1.5 A1.6 A1.7 A1.8 A1.9 A1.10 A1.11 A1.12 A1.13 A1.14 A1.99

Steering Limp Travel Full Travel Main Raise Main Lower Aux Raise Aux Lower Traverse Pivot Fork Extend E.D. Closed Full Hoist Brake - E.D. 1234567890123 YYYYYYYYYYYYY Escape

Figure 13921-01 Crown 2006 PF15239-5 Rev. 1/09

TSP 6000 Series

M4.3-1960-005 02 Rev. 1/09

177

ELECTRICAL SYSTEM ACCESS 123® Input Menus

A2 Inputs Menu Selections: A2.1 Load Handler A2.2 Platform (see page -008) A2.3 Seat Controls (see page -009) A2.4 Power Unit (see page -010) A2.99 Escape

1 Position (in) 2 Speed (in/sec) 3 Count (counts)

continued on page -007

1 Position (deg) 2 Speed (deg/sec) 3 Voltage (V)

Figure 13922-01

M4.3-1960-006 02 Rev. 1/09

178

TSP 6000 Series

Crown 2006 PF15239-6 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123®

from page -006

Closed or Open

1 Weight (lbs) 2 Current (mA) 3 Count (counts)

returns back to A2 Inputs

Figure 13923-01

Crown 2006 PF15239-7 Rev. 1/09

TSP 6000 Series

M4.3-1960-007 02 Rev. 1/09

179

ELECTRICAL SYSTEM ACCESS 123® Platform Menu

1 Position (in) 2 Speed (in/sec) 3 Count (counts) 99 Escape Closed or Open

BRS1 and BRS3

CHS1 and CHS2

CHS3 and CHS4

FPS1, 2 and 3

FPS4, 5 and 6

FPS7, 8 and 9

GTSL and GTSR

HGTRS1

SLS

SPS

KCC

ZSSA

ZSSB

ZSSC

returns back to A2 Inputs

Figure 13924-02

M4.3-1960-008 02 Rev. 1/09

180

TSP 6000 Series

Crown 2006 PF15239-8 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Seat Controls Menu

1 2 3 4 5

ECR & ECR2 (counts) POT1 (V) POT2 (V) POT3 (V) POT4 (V)

Open or Closed

returns back to A2 Inputs

Figure 13925-01 Crown 2006 PF15239-9 Rev. 1/09

TSP 6000 Series

M4.3-1960-009 02 Rev. 1/09

181

ELECTRICAL SYSTEM ACCESS 123® Power Unit Menu

1 ACCESS 5(rpm) 2 ACCESS 5 (counts) 3 ACCESS 3 (rpm) 4 Escape

continued on page -011

Figure 13926-02

M4.3-1960-010 02 Rev. 1/09

182

TSP 6000 Series

Crown 2006 PF15239-10 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123®

from page -010

Closed or Open Closed or Open

continued on page -012

Figure 13927-01

Crown 2006 PF15239-11 Rev. 1/09

TSP 6000 Series

M4.3-1960-011 02 Rev. 1/09

183

ELECTRICAL SYSTEM ACCESS 123®

from page -011

1 2 3 4 99

Battery (V) Steering (V) Inner Brake (V) Outer Brake (V) Escape

Closed or Open

1 2 99

Alarm Active Escape

Figure 13928-01

M4.3-1960-012 02 Rev. 1/09

184

TSP 6000 Series

Crown 2006 PF15239-12 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Outputs Menu

A3 Outputs Menu Selections: A3.1 Load Handler A3.2 Platform (see page -017) A3.3 Seat Controls (see page -017) A3.4 Power Unit (see page -018) A3.99 Escape

continued on page -014

Figure 13929-01 Crown 2006 PF15239-13 Rev. 1/09

TSP 6000 Series

M4.3-1960-013 02 Rev. 1/09

185

ELECTRICAL SYSTEM ACCESS 123® Load Handler Menu from page -013

continued on page -015

Figure 13930-01

M4.3-1960-014 02 Rev. 1/09

186

TSP 6000 Series

Crown 2006 PF15239-14 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® from page -014

continued on page -016

Figure 13931-01

Crown 2006 PF15239-15 Rev. 1/09

TSP 6000 Series

M4.3-1960-015 02 Rev. 1/09

187

ELECTRICAL SYSTEM ACCESS 123®

from page -015

returns back to A3 Outputs

Figure 13932-01

M4.3-1960-016 02 Rev. 1/09

188

TSP 6000 Series

Crown 2006 PF15239-16 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Platform Menu or Seat Controls Menu

OFF or ON

returns back to A3 Outputs

Figure 13933-02

Crown 2006 PF15239-17 Rev. 1/09

TSP 6000 Series

M4.3-1960-017 02 Rev. 1/09

189

ELECTRICAL SYSTEM ACCESS 123® Power Unit Menu

continued on page -019

Figure 13934-01

M4.3-1960-018 02 Rev. 1/09

190

TSP 6000 Series

Crown 2006 PF15239-18 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123®

from page -018

OFF or ON

continued on page -020 Figure 13935-02

Crown 2006 PF15239-19 Rev. 1/09

TSP 6000 Series

M4.3-1960-019 02 Rev. 1/09

191

ELECTRICAL SYSTEM ACCESS 123® from page -019

continued on page -021

Figure 13936-01

M4.3-1960-020 02 Rev. 1/09

192

TSP 6000 Series

Crown 2006 PF15239-20 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123®

from page -020

OFF or ON

returns back to A3 Outputs

Figure 13937-02

Crown 2006 PF15239-21 Rev. 1/09

TSP 6000 Series

M4.3-1960-021 02 Rev. 1/09

193

ELECTRICAL SYSTEM ACCESS 123® Test Outputs Menu

A4 Test Outputs Menu Selections: A4.1 Load Handler A4.2 Platform (see page -024) A4.3 Seat Controls (see page -024) A4.4 Power Unit (see page -025) A4.99 Escape test output active (2 sec) test output complete

test output active (2 sec) test output complete

continued on page -023 Figure 13938-01

M4.3-1960-022 02 Rev. 1/09

194

TSP 6000 Series

Crown 2006 PF15239-22 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Load Handler Menu from page -022

test output active (2 sec) test output complete

returns back to A4 Test Outputs

Figure 13939-01 Crown 2006 PF15239-23 Rev. 1/09

TSP 6000 Series

M4.3-1960-023 02 Rev. 1/09

195

ELECTRICAL SYSTEM ACCESS 123® Platform Menu or Seat Controls Menu

test output active (2 sec) test output complete

returns back to A4 Test Outputs

test output active (2 sec) test output complete

returns back to A4 Test Outputs

Figure 13940-01

M4.3-1960-024 02 Rev. 1/09

196

TSP 6000 Series

Crown 2006 PF15239-24 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Power Unit Menu

test output active (2 sec) test output complete

continued on page -026

Figure 13941-01 Crown 2006 PF15239-25 Rev. 1/09

TSP 6000 Series

M4.3-1960-025 02 Rev. 1/09

197

ELECTRICAL SYSTEM ACCESS 123®

from page -026 test output active (2 sec) test output complete

test output active (2 sec) test output complete

continued on page -027

Figure 13942-01

M4.3-1960-026 02 Rev. 1/09

198

TSP 6000 Series

Crown 2006 PF15239-26 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123®

from page -026

test output active (2 sec) test output complete

test output active (2 sec) test output complete test output active (2 sec) test output complete test output active (2 sec) test output complete

test output active (2 sec) test output complete

returns back to A4 Test Outputs

Figure 13943-01

Crown 2006 PF15239-27 Rev. 1/09

TSP 6000 Series

M4.3-1960-027 02 Rev. 1/09

199

ELECTRICAL SYSTEM ACCESS 123® Calibration Menu

Calibration Menu Selections: C1 Handles C2 Hydraulics (see page -030) C3 Height Cutouts (see page -043) C4 Steer Encoder (see page -044) C5 Wire Guide (see page -045)

continued on page -029 Figure 13944-01

M4.3-1960-028 02 Rev. 1/09

200

TSP 6000 Series

Crown 2006 PF15239-28 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Handles Menu

from page -028

Figure 13945-01 Crown 2006 PF15239-29 Rev. 1/09

TSP 6000 Series

M4.3-1960-029 02 Rev. 1/09

201

ELECTRICAL SYSTEM ACCESS 123® Hydraulics Menu

C2.1 C2.2 C2.3 C2.4 C2.5 C2.6 C2.7 C2.8 C2.9 C2.10 C2.11 C2.12 C2.13 C214

Traverse Sense Pivot Sense (see page -031) Main R Valve (see page -032 Main L Valve (see page -033) Main Hgt Sense (see page -034) Aux Flow Valve (see page -035) Traverse Valve (see page -036) Pivot Valve (see page -036) Extend Valve (see page -037) Aux R Valve (see page -038) Weight Sense (see page -039) Aux L Valve (see page -040) Aux Hgt Sense (see page -041) Tilt Valve (see page -042)

momentary message

Figure 13946-01

M4.3-1960-030 02 Rev. 1/09

202

TSP 6000 Series

Crown 2006 PF15239-30 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Pivot Sense Menu

momentary message

Figure 13947-01 Crown 2006 PF15239-31 Rev. 1/09

TSP 6000 Series

M4.3-1960-031 02 Rev. 1/09

203

ELECTRICAL SYSTEM ACCESS 123® Main R Valve Menu

This message occurs when you have reached the top and need to lower to continue.

Steps automatically from menu to menu.

momentary message

Figure 13948-01

M4.3-1960-032 02 Rev. 1/09

204

TSP 6000 Series

Crown 2006 PF15239-32 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Main L Valve

This message occurs when you have reached the bottom and need to raise to continue.

Steps automatically from menu to menu.

momentary message

Figure 13949-01 Crown 2006 PF15239-33 Rev. 1/09

TSP 6000 Series

M4.3-1960-033 02 Rev. 1/09

205

ELECTRICAL SYSTEM ACCESS 123® Main HGT Sense Menu

Message occurs if platform starts above reset.

momentary message

Figure 13957-01

M4.3-1960-034 02 Rev. 1/09

206

TSP 6000 Series

Crown 2006 PF15239-34 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Aux Flow Valve Menu

This message occurs when you have reached the top.

Steps automatically from menu to menu.

momentary message

Figure 13950-01 Crown 2006 PF15239-35 Rev. 1/09

TSP 6000 Series

M4.3-1960-035 02 Rev. 1/09

207

ELECTRICAL SYSTEM ACCESS 123® Traverse Valve Menu or Pivot Valve Menu

Finds breakout valve twice.

Message occurs if operator stops command.

momentary message

Figure 13951-01

M4.3-1960-036 02 Rev. 1/09

208

TSP 6000 Series

Crown 2006 PF15239-36 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Extend Valve

Message occurs if operator stops command.

Finds breakout valve twice.

momentary message

Figure 13952-01 Crown 2006 PF15239-37 Rev. 1/09

TSP 6000 Series

M4.3-1960-037 02 Rev. 1/09

209

ELECTRICAL SYSTEM ACCESS 123® Aux R Valve Menu

This message occurs when carriage has reached the top.

Steps automatically from menu to menu.

momentary message

Figure 13953-01

M4.3-1960-038 02 Rev. 1/09

210

TSP 6000 Series

Crown 2006 PF15239-38 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Weight Sense Menu

Steps automatically from menu to menu.

momentary message

Figure 13954-01 Crown 2006 PF15239-39 Rev. 1/09

TSP 6000 Series

M4.3-1960-039 02 Rev. 1/09

211

ELECTRICAL SYSTEM ACCESS 123® Aux Valve Menu Note: You should have 91 to 227 kg (200 to 500 lbs) on forks for this calibration.

This message occurs when forks have reached the bottom and need to return to top.

Steps automatically from menu to menu

momentary message

Figure 13955-01

M4.3-1960-040 02 Rev. 1/09

212

TSP 6000 Series

Crown 2006 PF15239-40 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Aux HGT Sense Menu

Message occurs if fork start above reset.

momentary message

Figure 13956-01

Crown 2006 PF15239-41 Rev. 1/09

TSP 6000 Series

M4.3-1960-041 02 Rev. 1/09

213

ELECTRICAL SYSTEM ACCESS 123® Tilt Valve Menu

momentary message

This message occurs when command is released

Figure 13958-01

M4.3-1960-042 02 Rev. 1/09

214

TSP 6000 Series

Crown 2006 PF15239-42 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Height Cutouts Menu

C3 Height Cutouts Menu Selections: C3.1 Cutout 1 C3.2 Cutout 2 C3.3 Cutout 3 C3.4 Cutout 4 C3.5 Cutout 5 C3.6 Cutout 6

None PCT - Raise Cutout with Override PST - Raise Cutout without Override NCT - Lower Cutout with Override Menu flow is the same for all Cutout Menus.

Always or FR Only

A, B, C or ALL Menu occurs if Zone Select is set in Features Menu.

1 No Save 2 Yes Save Values 3 Clear All

Figure 13959-02 Crown 2006 PF15239-43 Rev. 1/09

TSP 6000 Series

M4.3-1960-043 02 Rev. 1/09

215

ELECTRICAL SYSTEM ACCESS 123® Steer Encoder Menu

returns to Calibration: C4 Steer Encoder menu

Figure 13960-01

M4.3-1960-044 02 Rev. 1/09

216

TSP 6000 Series

Crown 2006 PF15239-44 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Wire Guide Menu

C5 Wire Guide Menu Selections:

C5.1 Calibrate C5.2 Adjust X-Offset (see page -049)

1 No Save 2 Yes Save Values 3 Load Defaults

Figure 13961-01 Crown 2006 PF15239-45 Rev. 1/09

TSP 6000 Series

M4.3-1960-045 02 Rev. 1/09

217

ELECTRICAL SYSTEM ACCESS 123® Calibrate Menu GUS = Manual

GUS = Auto

Default Setting Soft = 1 Quick = 9 GUS = Manual

GUS = Auto Drive truck over an active guide wire at a shallow angle (i.e. 5° or less) at least two times. Both sensor bars must completely cross over the wire. If plssible, perform sensor coil calibration on a wire with a high field strength.

No audible alarm. GUS = Auto

Recommended checks for saturated coil(s): 1) Verify that field strength meets Crown’s recommendations. 2) Verify that sensor bars are mounted 82 - 86 mm (3.25 - 3.38 in) from floor.

A saturated coil does mot invalidate sensor coil calibration. If a sensor bar is re-positioned or field strength is adjusted, select escape and re-do sensor coil calibration

Continued on page 47

Figure 13962-02

M4.3-1960-046 02 Rev. 1/09

218

TSP 6000 Series

Crown 2006 PF15239-46 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® from page - 046 Travel Request = Forks Leading direction

Travel Request = Forks Trailing direction

Directional Change (travel distance is additive)

Travel distance reached in either Forks Leading or Forks Trailing direction

Screen states either Leading or Trailing; it is dependent upon which travel direction reaches 18 m (60 ft) first. Audible alarm is a single beep. Travel Request in the non-completed direction

Travel Request in the completed direction

Screen states either Leading or Trailing; it is dependent upon which travel direction hasn’t reached 18 m (60 ft) first. Travel distance completed in both directions Screen states either Leading or Trailing; it is dependent upon which travel direction reaches 18 m (60 ft) last. Audible alarm is a single beep. Travel speed < 0.16 km/h (0.1 mph)

continued on page 48 GUS = Manual GUS = Auto

Figure 13963-02

Crown 2006 PF15239-47 Rev. 1/09

TSP 6000 Series

M4.3-1960-046 02 Rev. 1/09

219

ELECTRICAL SYSTEM ACCESS 123®

from page -047 Travel Request = Forks Leading direction

Travel Request = Forks Trailing direction

Directional Change (travel distance is additive) Travel distance reached in either Forks Leading or Forks Trailing direction

Screen states either Leading or Trailing; it is dependent upon which travel direction reaches 18 m (60 ft) first. Audible alarm is a single beep. Travel Request in the non-completed direction

Travel Request in the completed direction Screen states either Leading or Trailing; it is dependent upon which travel direction hasn’t reached 18 m (60 ft) first.

Travel distance completed in both directions Screen states either Leading or Trailing; it is dependent upon which travel direction reaches 18 m (60 ft) last. Audible alarm is a single beep. Travel speed < 0.16 km/h (0.1 mph)

GUS = Manual returns back to C5 Wire Guide 1 Calibrate menu Figure 13964-02

M4.3-1960-048 02 Rev. 1/09

220

TSP 6000 Series

Crown 2006 PF15239-48 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Adjust X-Offset Menu

GUS = Manual

GUS = Auto

When entering x-offset calibration, x-offset value is set to zero in both travel directions.

Truck stops before reaching 12 m (40 ft)

Travel Request = Forks Leading direction

Travel request = Forks Trailing direction

Travel distance reset to zero when truck stops Travel distance reached in either Forks Leading or Forks Trailing direction

Screen states either Leading or Trailing; it is dependent upon which travel direction has reached 12 m (40 ft) first. Audible alarm is a single beep.

Travel speed < 0.16 km/h (0.1 mph)

Screen states either Right or Left. Screen will display direction selected last.

Travel request

English units

Metric units

Two numeric values have been entered Max value = 32 (32 = 2.0 in)

Max value = 50 Travel request

enter Save Guidance to complete the save process

Figure 13965-02 Crown 2006 PF15239-49 Rev. 1/09

TSP 6000 Series

M4.3-1960-049 02 Rev. 1/09

221

ELECTRICAL SYSTEM ACCESS 123® Features Menu

Features Menu Selections: F1 Truck Model F2 Mast Type (see page -051) F3 Measurement (see page -051) F4 Collapsed Height (see page -051) F5 Lift Height (see page -051) F6 Traverse Frame (see page -051) F7 Fork Type (see page -053) F8 Fork Length (see page -054) F10 Pallet Width (see page -054) F11 Pallet Length (see page -054) F12 Battery Compartment (see page -054) F13 Truck Weight (see page -055) F14 Max Load (see page -055) F15 Lift Motor (see page -055) F16 Capacity Data Monitor (see page -056) F17 Wire Guidance (see page -057) F18 Manual Wire Sense (see page -057) F19 End Aisle Sense (see page -058) F20 Battery Retainer Sw (see page -058) F21 Travel Alarm (see page -058) F22 not available (see page -059) F23 Language (see page -059) F24 User Performance (see page -060) F25 User Codes (see page -060) F26 Cold Condition (see page -061) F27 Options (see page -063) F28 Front Rail (see page -063) F29 Zone Switch (see page -063) F30 Aux Mast (see page -063) F31 Screen Setup (see page -063) F99 Save (see page -063)

Figure 13966-01

M4.3-1960-050 02 Rev. 1/09

222

TSP 6000 Series

Crown 2006 PF15239-50 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Mast Type, Measurement, Collapsed Height , Lift Height or Traverse Frame Menu

Default Setting

Default setting Min = 112 Max = 325

Default Setting Min = 181 Max = 607

Default Setting

Default Setting Min = 48 Max = 90

Figure 13967-01

Crown 2006 PF15239-51 Rev. 1/09

TSP 6000 Series

M4.3-1960-051 02 Rev. 1/09

223

ELECTRICAL SYSTEM ACCESS 123® Fork Type Menu

Default Setting Default Setting = 30 Min = 30 Max = 66

Default Setting = 5 Min = 3 Max = 12

Default Setting = 30 Min = 30 Max = 66

continued on page 053

Figure 13968-01

M4.3-1960-052 02 Rev. 1/09

224

TSP 6000 Series

Crown 2006 PF15239-52 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123®

continued from page 052

Default Setting = 5 Min = 3 Max = 12

Default Setting Min = 30 Max = 66

Figure 14923

Crown 2006 PF15239-53 Rev. 1/09

TSP 6000 Series

M4.3-1960-053 02 Rev. 1/09

225

ELECTRICAL SYSTEM ACCESS 123® Fork Length, Pallet Width, Pallet Length or Battery Compartment Menu

Default Setting Min = 30 Max = 60

Default Setting Min = 23 Max = 99 Default Setting

Default Setting Min = 30 Max = 112

Default Setting Min = 30 Max = 82

Figure 13969-01

M4.3-1960-054 02 Rev. 1/09

226

TSP 6000 Series

Crown 2006 PF15239-54 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Truck Weight, Max Load or Lift Motor Menu

Default Setting Min = 12,000 Max = 24,000

Default Setting Min = 500 Max = 3500

Default Setting Default Setting

Figure 13992-01

Crown 2006 PF15239-55 Rev. 1/09

TSP 6000 Series

M4.3-1960-055 02 Rev. 1/09

227

ELECTRICAL SYSTEM ACCESS 123® Capacity Data Monitor Menu

Default Setting

Default = 3000 Min = 500 Max = 3500

Default Setting= 0 Min = 0 Max = 4

Default = 207 Min = 181 Max = 607

Default Setting = 207 Min = 181 Max = 607

Default = 3000 Min = 500 Max = 3500

Default Setting = 3000 Min = 500 Max = 3500

Default = 207 Min = 181 Max = 607

Default Setting = 207 Min = 181 Max = 607

Default = 3000 Min = 500 Max = 3500

Figure 13993-01

M4.3-1960-056 02 Rev. 1/09

228

TSP 6000 Series

Crown 2006 PF15239-56 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Wire Guidance or Manual Wire Sense Menu

Default Setting

Default = 5 Min = 5 Max = 20

Figure 13994-01

Crown 2006 PF15239-57 Rev. 1/09

TSP 6000 Series

M4.3-1960-057 02 Rev. 1/09

229

ELECTRICAL SYSTEM ACCESS 123® End Aisle, Battery Retainer SW or Travel Alarm Menu

Default Setting

Figure 13995-01

M4.3-1960-058 02 Rev. 1/09

230

TSP 6000 Series

Crown 2006 PF15239-58 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Language or User Performance Menu

Default Setting

Figure 13996-01

Crown 2006 PF15239-59 Rev. 1/09

TSP 6000 Series

M4.3-1960-059 02 Rev. 1/09

231

ELECTRICAL SYSTEM ACCESS 123® User Codes or Cold Condition Menu

Default Setting

Figure 13997-01

M4.3-1960-060 02 Rev. 1/09

232

TSP 6000 Series

Crown 2006 PF15239-60 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Options Menu

Default Setting

see page -062

Figure 13998-01

Crown 2006 PF15239-61 Rev. 1/09

TSP 6000 Series

M4.3-1960-061 02 Rev. 1/09

233

ELECTRICAL SYSTEM ACCESS 123®

continued from page 061

Default Setting

Figure 13999-01

M4.3-1960-062 02 Rev. 1/09

234

TSP 6000 Series

Crown 2006 PF15239-62 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Front Rail, Zone Switch, Aux Mast, Screen Setup or Save Menu Default = 69 Min. = 69 Max = 114 Default Setting

Default = ON Settings = OFF or ON

Default Setting

Default = OFF Settings = OFF or ON

Default = ON Settings = OFF or ON

Default = OFF Settings = OFF or ON

Figure 14000-02

Crown 2006 PF15239-64 Rev. 1/09

TSP 6000 Series

M4.3-1960-063 02 Rev. 1/09

235

ELECTRICAL SYSTEM ACCESS 123® Hour Meters Menu

Hour Meters Menu Selections: H1 Truck Runtime H2 Traction Motor H3 Hydraulic Motor H4 Steer Motor H5 ACCESS 1 H6 ACCESS 2 H7 ACCESS 3 H8 ACCESS 4 H9 ACCESS 5 H10 ACCESS 6 H11 ACCESS 7 H12 ACCESS 8

Figure 13705-02

M4.3-1960-064 02 Rev. 1/09

236

TSP 6000 Series

Crown 2006 PF15239-65 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Event Codes Menu

Figure 13706-01

Crown 2006 PF15239-66 Rev. 1/09

TSP 6000 Series

M4.3-1960-065 02 Rev. 1/09

237

ELECTRICAL SYSTEM ACCESS 123® Performance Menu

Performance Menu Selections: P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13

Setup P1 Setup P2 (see page -069) Setup P3 (see page -071) Plug (see page -072) Coast (see page -073) Braking (see page -073) Free Range Speeds (see page -073) Guided Speed (see page -074) BDI (see page -074) EAC Setup (see page -075) Main Hoist R or L (see page -077) Aux Hoist R or L (see page -078) PDS Setup (see page -079) Default = 9 Min = 1 Max = 9

Default = 7 Min = 1 Max = 9

Default = 5.5 Min = 1.0 Max = 5.5

see page 067

see page -068

Figure 14001-02

M4.3-1960-066 02 Rev. 1/09

238

TSP 6000 Series

Crown 2006 PF15239-67 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® P1 Setup P1 Menu from page -066

Default = 6.5 Min = 1.0 Max = 6.5

Default = 6.0 Min = 1.0 Max = 6.0

Default = 7.5 Min = 1.0 Max = 7.5

Figure 14002-01

Crown 2006 PF15239-68 Rev. 1/09

TSP 6000 Series

M4.3-1960-067 02 Rev. 1/09

239

ELECTRICAL SYSTEM ACCESS 123®

from page -066

Default = 5 Min = 1 Max = 9

Default = 9 Min = 1 Max = 9

Default = 5 Min = 1 Max = 9

Default = 7 Min = 1 Max = 9

Figure 14003-01

M4.3-1960-068 02 Rev. 1/09

240

TSP 6000 Series

Crown 2006 PF15239-69 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® P2 Setup P2 Menu Default = 5.0 Min = 1.0 Max = 5.5

Default = 7 Min = 1 Max = 9

Default = 5 Min = 1 Max = 9

Default = 6.0 Min = 1.0 Max = 6.5

see page -070 Default = 5.5 Min = 1.0 Max = 6.0

Default = 6.5 Min = 1.0 Max = 7.5

Figure 14004-01 Crown 2006 PF15239-70 Rev. 1/09

TSP 6000 Series

M4.3-1960-069 02 Rev. 1/09

241

ELECTRICAL SYSTEM ACCESS 123®

see page -069

Default = 5 Min = 1 Max = 9 Default = 4 Min = 1 Max = 9

Default = 7 Min = 1 Max = 9 Default = 5 Min = 1 Max = 9

Default = 4 Min = 1 Max = 9

Figure 14005-01

M4.3-1960-070 02 Rev. 1/09

242

TSP 6000 Series

Crown 2006 PF15239-71 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® P3 Setup P3 Menu Default = 4.5 Min = 1.0 Max = 5.5

Default = 5 Min = 1 Max = 9

Default = 3 Min = 1 Max = 9

Default = 5.0 Min = 1.0 Max = 6.5

see page -072

Default = 4.5 Min = 1.0 Max = 6.0

Default = 6.0 Min = 1.0 Max = 7.5

Figure 14006-01

Crown 2006 PF15239-72 Rev. 1/09

TSP 6000 Series

M4.3-1960-071 02 Rev. 1/09

243

ELECTRICAL SYSTEM ACCESS 123®

see page -071

Default = 3 Min = 1 Max = 9 Default = 3 Min = 1 Max = 9

Default = 5 Min = 1 Max = 9 Default = 5 Min = 1 Max = 9

Default = 3 Min = 1 Max = 9

Figure 14007-01

M4.3-1960-072 02 Rev. 1/09

244

TSP 6000 Series

Crown 2006 PF15239-73 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Plug, Coast, Braking or Free Range Speeds Menu Default = 7 Soft = 1 Aggressive = 9 Default = 7 Soft = 1 Aggressive = 9 Default = 9 Shortest = 1 Longest = 9 Default = 7 Soft = 1 Aggressive = 9

Default = 600 Min = 0 Max = 600

Figure 14008-01

Crown 2006 PF15239-74 Rev. 1/09

TSP 6000 Series

M4.3-1960-073 02 Rev. 1/09

245

ELECTRICAL SYSTEM ACCESS 123® Guided Speeds Menu

Default = 600 Min = 0 Max = 600

Default = 2.5 Min = 1.5 Max = 2.5

Default = 5 Deepest Discharge = 1 Lowest Discharge = 9

Figure 14009-01

M4.3-1960-074 02 Rev. 1/09

246

TSP 6000 Series

Crown 2006 PF15239-75 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® EAC Setup Menu

see page -076

Figure 14010-01 Crown 2006 PF15239-76 Rev. 1/09

TSP 6000 Series

M4.3-1960-075 02 Rev. 1/09

247

ELECTRICAL SYSTEM ACCESS 123®

see page -075

Default = 2.0 Min = 1.0 Max = 6.0

Default = 3 Min = 1 Max = 9

Default = 5 Min = 1 Max = 9

Default = 45 Min = 10 Max = 60

Default = 20 Min = 0 Max = 40

Figure 14011-01

M4.3-1960-076 02 Rev. 1/09

248

TSP 6000 Series

Crown 2006 PF15239-77 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Main Hoist R or L Menu Default = 9 Min = 1 Max = 9

Default = 6 Soft = 1 Quick = 9

Default = 7 Soft = 1 Quick = 9

Default = 9 Min = 1 Max = 9

Default = 6 Soft = 1 Quick = 9

Default = 7 Soft = 1 Quick = 9

Figure 14012-01

Crown 2006 PF15239-78 Rev. 1/09

TSP 6000 Series

M4.3-1960-077 02 Rev. 1/09

249

ELECTRICAL SYSTEM ACCESS 123® PDS SETUP MENU

Aux Hoist R or L Menu

Default = 6 Soft = 1 Quick = 9

Default = 7 Soft = 1 Quick = 9

Default = 6 Soft = 1 Quick = 9

Default = 7 Soft = 1 Quick = 9

Figure 14013-01

PDS Setup Menu

M4.3-1960-078 02 Rev. 1/09

250

TSP 6000 Series

Crown 2006 PF15239-79 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123®

Default = 6.0 Min = 1.0 Max = 6.5

Default = 1.5 Min = 1.0 Max = 6.0

Default = 9 Min = 1 Max = 9

Default = 6.0 Min = 1.0 Max = 7.5

Default = 1.5 Min = 1.0 Max = 6.0

Default = 9 Min = 1 Max = 9

Figure 14014-01

Crown 2006 PF15239-80 Rev. 1/09

TSP 6000 Series

M4.3-1960-079 02 Rev. 1/09

251

ELECTRICAL SYSTEM ACCESS 123® Utilities Menu

Utilities Menu Selections: U1 Part Numbers U2 Activate Tow Mode (see page -081) U3 Shipping Mode (see page -081) U4 Truck Lockout (see page -081) U5 Traverse Valve (see page -081) U99 Escape

U1 Part Numbers Menu Selections: U1.1 ACCESS 1 U1.2 ACCESS 2 U1.3 ACCESS 3 U1.4 ACCESS 4 U1.5 ACCESS 5 U1.6 ACCESS 6 U1.7 ACCESS 7 U1.8 ACCESS 8 U1.9 Vehicle

Figure 14015-02

M4.3-1960-080 02 Rev. 1/09

252

TSP 6000 Series

Crown 2006 PF15239-81 Rev. 1/09

ELECTRICAL SYSTEM ACCESS 123® Active Tow Mode, Shipping Mode, Truck lockout or Traverse Valve Menu

Upon entering U2.1 Tow Mode, tow mode is immediately active. Display should read: “Tow Mode Activated” “Key Down to Remove”

“Key Down to Enable”

“Key Down to Disable”

“Key Down to Enable”

“Key Down to Disable”

Figure 14016-01

TSP 6000 Series

M4.3-1960-081 02 Rev. 1/09

253

ELECTRICAL SYSTEM Wire Guidance

Wire Guidance The Wire Guidance System automatically steers the truck down the aisle without the use of guide rails. A Line Driver (1) produces a set frequency of 5.2 kHz, 6.25 kHz, 7.0 kHz, or 10 kHz which is transmitted through wire embedded in the floor (5) down the middle of each aisle. The generated signal is transmitted through the embedded wire (3), as shown in Figure 7747-01. 1

which act as antennas to receive a transmitted signal. The closer a coil gets to being directly over the wire, the higher the amplitude of signal received by the coil. Using the coil signal amplitude comparisons, the truck will "sense" the signal path. With this data, steering is electronically controlled to follow the signal. The wire guidance selector switch (GUS) in the R. H. armrest selects manual or automatic steering. When in the manual mode, truck steering is controlled by the operator. Steering remains in the operator's control when switching to automatic until the guidance signal is detected. When guidance signal is detected, steering control is automatically changed to the guidance system. To align a truck to the wire guide signal, turn wire guidance switch (GUS) to on. The approach angle must be no greater than 30° and traction speed should be below 2.4 km/h (1.5 mph) Refer to Figure 12911. The brakes are automatically applied when the approach angle is exceeded in the automatic mode. If the approach speed is greater than 2.4 km/h, the truck will decelerate to 2.4 km/h (1.5 mph). Traction speed is limited to 2.4 km/h (1.5 mph) in the automatic mode until the truck is aligned with the wire. When aligned, the acquisition speed limit is removed and the applicable speed vs. height curve will be in force.

1 1

Figure 7747-01 1

Line Driver

Storage Racks

Embedded Wire

Transmitted Signal

Floor

Epoxy

Wire Embedded in Floor (Sawcut)

Figure 12911-01

Sensor bars mounted on the centerline of both ends of the truck, near the floor, (See Figure) contain coils M4.3-1960-500 02 Rev. 10/06

254

Maximum Approach (Angle is 30°)

Load Wheel Sensor Bar

Steer Wheel Sensor Bar

TSP 6000 Series

Crown 2005 PF15114-1 Rev. 10/06

ELECTRICAL SYSTEM Wire Guidance Some conditions that might cause an automatic slow down while traveling on wire guidance are:

Operation Modes

•

Low signal strength from wire

Manual

•

Truck deviates slightly from wire

•

End of Aisle Control (EAC) (Optional) is activated.

When wire guidance selector switch (GUS) is in the "manual" position, truck steering is in the operator's control.

Some conditions that might cause an automatic stop while traveling on wire guidance are:

Automatic

•

Signal strength from wire is lost or too low.

•

Acquiring the wire at an angle greater than 30°.

•

Truck deviates too far from wire.

•

End of Aisle Control (EAC) (Optional) is activated.

When wire guidance selector switch (GUS) is placed in the "automatic" position, the electronics enter the Search mode. At this time the guidance signal has not been detected by the sensors. The "auto" and "manual" indicators are both on and traction speed is limited to 2.4 km/h (1.5 mph). Steering control remains in the manual mode.

Each sensor bar contains four coils which act as separate antennas. When the amplitude of guidance signals received are compared, the higher amplitude signals are from the coils in closer proximity to the embedded wire. The sensors mounted on the truck electronically "sense" where the truck is in reference to the guidance signal. When wire guidance selector switch (GUS) is in the "automatic" mode, the steering module provides the correct polarity and amplitude of voltage to the steering motor to keep the truck centered over the guidance signal. Feedback from the steering feedback encoder (ECR-6) verifies the steered wheel is turned in the direction required. Whenever wire guidance signal strength drops to near the minimum required to guide the truck, the guidance module outputs a signal to illuminate the signal strength light on the display (Signal). The steering module sends the signal to the traction controller for 2.4 km/h (1.5 mph) maximum traction speed. If signal strength returns, the signal strength indicator is turned off and the traction speed limit is removed. If there is loss of the guidance signal, or if signal strength is below the minimum required to guide the truck, the guidance module will output signals to operate the alarm and apply the brake. It will also turn the "automatic" indicator off and turn the "manual" indicator on. The wire guidance selector switch (GUS) must be placed in the "manual" position to release the brake.

When either sensor bar detects the guidance signal, Auto Acquisition mode will be indicated by a display change and a 1 second audible alarm. If traction speed at this time is greater than 2.4 km/h (1.5 mph) the truck will decelerate to 2.4 km/h (1.5 mph). If the angle of the truck to the wire is greater than 30°, the brakes will be applied. To release the brakes, guidance selector switch (GUS) must be placed in the manual position. If the angle of the truck is within the limits when the signal is detected, the manual indicator is turned off and steering is controlled by the electronics. Traction speed is still limited to 2.4 km/h (1.5 mph). When traveling in either direction the guidance system will align the truck with the wire when all of the parameters are met: truck less than 19 mm (0.75 in) from wire, truck angle less than 1° and the steer wheel less than 6° from center. When the truck is adequately aligned, the auto tracking mode is indicated by a 2 second operation of the alarm. In this mode the truck is automatically guided by the electronics and the acquisition speed limit is removed. Three variations to normal operation are encountered during the Auto Tracking mode:

•

Auto Field Strength

•

Auto Track Deviation

•

Auto Wire Lost

Auto Field Strength variation is encountered when the guidance signal received by the sensors decreases to near the minimum required to continue Auto Tracking Mode. When entering Auto Field Strength, the alarm is pulsating, field strength indicator is turned on and traction speed is limited to 2.4 km/h (1.5 mph).

Crown 2005 PF15114-2 Rev. 10/06

TSP 6000 Series

M4.3-1960-501 02 Rev. 10/06

255

ELECTRICAL SYSTEM Wire Guidance When the guidance signal received returns to above minimum levels, the alarm stops pulsating, the field strength indicator turned off and the speed limit removed. Auto Track Deviation is encountered if the center of the truck leaves the guidance signal by 19 - 38 mm (.75 - 1.50 in), a truck angle of 1 - 1.8° or the steer wheel angle is 6 - 12° from center. When this happens, the alarm is sounded (pulsates), and traction speed is limited to 2.4 km/h (1.5 mph). When truck returns to acceptable tracking characteristics, the alarm stops pulsating and is sounded for 2 seconds to indicate auto tracking mode, and traction speed limit is removed. Auto Wire Lost will occur if one or more of four situations are present; 1) guidance signal lost; 2) centerline of truck leaves signal path by more than 38 mm (1.50 in); 3) angle of truck to guidance signal is more than 1.8°; 4) steer wheel angle is more than 12°during Auto Tracking. The truck is allowed to deviate more immediately following a travel direction change. When in Auto Wire Lost, the alarm is operated continuously and the brake is applied. Guidance selector switch (GUS) must be placed in the "manual" position to release the brakes after this situation occurs.

Sensor Bar

Truck Centerline

Floor

Guidewire

Distance 82 to 86 mm (3.25 to 3.38 in)

Line Driver Output Verify the line driver output signal is of the correct amplitude prior to performing an alignment on the truck. Crown has designed a field strength meter for use in setting up and/or checking guide wire signal strength (5.0 kHz to 10.0 kHz) in wire guidance installations.

Sensors Sensor bars (1) are fastened to adjustable brackets which permit adjusting the distance (5) between the sensor bars and the floor. When the line driver current output is set to 220 ma., the sensor bar (1) should be level and 82 to 86 mm (3.25 to 3.38 in) from the floor (3). Refer to Figure 12912. Voltage required by the sensor bar to operate is 5 V, between terminals 5 (positive) and 3 (negative).

The field strength meter, Crown part number 112953, will indicate actual peak to peak voltage of the radiated signal from the guide wire in the floor. This reading represents what the truck is seeing when the sensors are set at the recommended height from the floor. Refer to the Field Strength Cross Reference chart for optimum field strength values.

Figure 1550-01

4 Figure 12912-01

M4.3-1960-503 02 Rev. 10/06

256

TSP 6000 Series

Crown 2005 PF15114-3 Rev. 10/06

ELECTRICAL SYSTEM Wire Guidance Field Strength Cross Reference Chart 1

Frequency (kHz)

Field Strength Values

6.25

168 - 190

5.2

100 - 118

7.0

168 - 190

10.0

100 - 120

Calibration Wire guidance calibration sets up components of the wire guidance system to guide the truck automatically while centered over the signal wire embedded in the floor. It is important to calibrate the truck at the installation with the highest field reading. If the truck has been calibrated on a wire at the lowest strength, the system can become saturated and allow the truck to weave more on a wire with a higher field strength.

Figure 7747-01 1

Line Driver

Storage Racks

Embedded Wire

Transmitted Signal

Floor

Epoxy

Wire Embedded in Floor (Sawcut)

Components which affect wire guidance calibration include the front and rear sensor bars, the guidance module, the steering module and the steering angle feedback encoder (ECR-6).

NOTE Whenever any of these components are changed or adjusted, the wire guidance system must be recalibrated. Wire guidance calibration consists of four parts:

Crown recommends calibration of this meter annually, and will perform this service free. Any repairs needed for calibration will incur a reasonable charge. Please allow a minimum of two weeks for normal calibration. Meters needing repair may require additional time. Meters will be returned freight collect. For information regarding the field strength meter, refer to Technical Service Bulletin No. 317. The Crown line driver is equipped with a current meter which accurately displays the line current within the conductor. This reading, however, due to floor conditions (wire depth, metal reinforcement material, electrical conduit, etc.) may not indicate the actual field strength. Therefore, to meet the field strength required to properly guide the vehicle, the line driver output will have to be adjusted. Refer to the Installation of Wire Guidance Line Driver Instructions, PF6669. Crown 2005 PF15114-4 Rev. 10/06

•

Peak sensor coil search

•

Steer wheel position

•

Truck angle

•

X-offset position.

Peak sensor coil search determines the maximum coil value of each coil when passed over an active guide wire. The maximum values are compared and each channel is given a value to be multiplied by so all coils will appear equal (at least 90). This is electronic correction for weak coils. Steer wheel position calibration determines the steer wheel center position which will provide straight line travel. Truck angle calibration determines angular deviation of the truck assembly which would cause "dog-tracking".

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ELECTRICAL SYSTEM Wire Guidance X-offset position calibration positions the mechanical center of the truck over the guidance signal. Wire guidance calibration procedures are performed by following the instructions on the display module. Wire guidance calibration is found in the calibration menu. Wire guidance calibration is only accessible in the "one-button" mode.

Also ensure the sensor bar height and line amplitude, measured with a field strength meter (112953), is correct as described earlier in this section.

Troubleshooting Components concerned with wire guidance are functionally checked by the software diagnostics and are covered by service numbers 631 thru 639. Refer to the Infopoint Quick Reference Guide for all troubleshooting and diagnostic information. Two conditions can exist which would cause unsatisfactory wire guidance performance by not tracking properly:

•

Incorrect feedback information from the steering feedback assembly

•

Saturated sensor bar coils

The incorrect feedback information in the first condition can occur if the steer wheel moves without turning the encoder input shaft or from a misaligned feedback encoder. To check to see if the coils in the sensor bars are saturated as stated in the second condition, enter the analyzer mode. The analyzer mode is for inputs accessible in the "one-button" mode. The scaled coil values can be reviewed by scrolling to A2 inputs then A2.4 power unit. The four scaled coil values for the steered wheel sensor bar are displayed on one screen. The same would be for the load wheel sensor bar. View the scaled coil values with the truck centered over the wire. The outboard sensor raw and scaled values will be substantially lower than the inboard sensor values, due to signal appearance. Drive the truck over the guide wire at a shallow angle (i.e. 5° or less). When each individual coil is directly over the guide wire, record the maximum scaled value. If the coils are saturated (i.e. values of 99%) or the maximum scaled values for the four coils are not within 10% of one another, perform the wire guidance procedure. When performing peak sensor coil search, both sensor bars must sweep completely across the guide wire.

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Crown 2005 PF15114-5 Rev. 10/06

ELECTRICAL SYSTEM End Aisle Control (EAC)

End Aisle Control (EAC) The purpose of the End Aisle Control (EAC) system is to remind the operator that the end or intersection of a warehouse aisle is approaching. This system incorporates magnets in the warehouse floor and magnetic sensors on the truck. Upon detection of the magnets, when approaching the end of the aisle, the sensors send a signal to the truck's Acess123 system to apply a traction plug condition to slow the vehicle. A text message indicating EAC zone entered is displayed on the operator display End Aisle Control is divided into two modes of operation. The Auto Guide mode is in force when the truck is in wire or rail guide tracking mode. Traction speed is controlled by the fork height versus speed curve. The End of Aisle, Auto Guided mode is in force when a truck, in wire or rail guide tracking mode detects the magnets while traveling toward the end of aisle. The End of Aisle result is selectable as stop or slowdown via plug or brake. A traction automatic speed resume is a selectable feature. This feature will automatically release the traction speed limit actuated by EAC zone and once the truck has traveled its preset distance beyond the EAC magnets.

The EAC system consists of a front bumper sensor bar which includes four sensors and sensor distribution board, Access 5 and Access 6 and the ORS1 override button in the L. H. multi-function handle. Figure 21241 provides a pictorial view of some components involved with end aisle control. The sensor bracket containing four sensors is mounted to the main frame of the truck, in the front bumper. Sensors A1 and B1 activate during travel in the forward (forks first) direction and sensors A2 and B2 active in the reverse (power unit first) direction. A text message appears on the operator display to provide an indication of when the truck enters or operates in an end of aisle control area. Sensors are positioned to place the A sensors 200 mm (8.0 in) from truck's centerline and B sensors 305 mm (12 in) from truck's centerline on a standard application. In a special application the A sensors can be positioned any distance more than 200 mm (8.0 in) from truck's centerline provided the B sensors are a minimum of 100 mm (4.0 in) from the A sensors. Different sensors must be used for sensing north or south magnetic poles. Sensors for sensing north magnetic poles are standard.

Figure 21241 1

Manual Override Switch (ORS1)

End Aisle Sensors Reverse Direction (Power Unit First)

Front Bumper

End Aisle Sensors Forward Direction (Forks First)

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ELECTRICAL SYSTEM End Aisle Control (EAC) Located in the center of the front bumper is a distribution module for interconnection of the EAC components. Connector location and applicable sensor interconnection is shown in Figure 21242. Signals from the sensors and EAC distribution module are connected to CA602, pins 1 through 14 on wire guidance module.

EAC Distribution Module

To Wire Guidance Module CA602 Pins1 through 14

Figure 21242

Wire Guidance Calibration Speeds Peak sensor wire guidance calibration is performed in manual steering mode. End Aisle operations, are not active in peak calibration (End Aisle Slowdown or Stop), however, speeds are clamped to maximum or 2.4 km/h (1.5 mph) offset wire guidance calibration is performed in guided, therefore EAC control is active. EAC Zones:

•

Zone 1 - Out of Aisle or Entering Aisle

•

Zone 2 - Center of Magnets

•

Zone 3 - Out of Aisle or Exiting Aisle

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Troubleshooting EAC components are monitored by system software and will log a fault into memory whenever a problem with the EAC system occurs: EAC Event Codes:

•

568 - EAC Hardware Fault

•

569 - EAC Sensor Latched ON

•

570-572 - EAC Sensor Latched ON

•

573-574 - EAC Magnet Missed

•

652-659 - EAC Sensor Signal Range Fault

•

660-663 - EAC Sensor Digital Fault

•

664-667 - EAC Weak Magnet Fault

•

668-671 - EAC Sensor Hardware Fault

•

672 - EAC Multiple Sensors Active Fault

Codes 568 through 574 and 652 through 672 all pertain to the EAC system issues. Two menu items in 1-Button mode can be used to determine fault cause. The first shows the state of the digital threshold detection. Anyone of the four sensors can be analyzed. The state of the digital input shall change as the truck passes over its corresponding magnet. The second is a display of the active sensor signal strength. It is presented as a percentage of full scale. The system has shown that the EAC system works reliably with sensors demonstrating a wide variation of reported peak signal strength. If issues are realized verify the height of the sensors above the floor, the distance of the center line of guidance bars to the EAC sensors and proper magnet positioning. Distance off the floor should be 18 to 25 mm (0.69 to 1.0 in).

TSP 6000 Series

Crown 2005 PF15116-2 Rev. 1/09

ELECTRICAL SYSTEM End Aisle Control (EAC) Termination Point Locations

Access 6 (Wire Guidance Module) - CA602 Pins 1 - 14

Access 5 (EAC Distribution Module) CA605, CA606, CA607, CA608, CA609 & CA610 EAC Sensor A1 - CA606 EAC Sensor A2 - CA609 EAC Sensor B1 - CA605 EAC Sensor B2 - CA610 Access 6 (Wire Guidance Module) - CA602 Pins 1 - 14 CA602-1

+12 V EAC Sensor Power

CA602-2

EAC Sensor Battery Negative

CA602-3

EAC A1 Test Approximately 7 V In Test Mode

CA602-4

EAC A1 Analog 0 - 5 V When Over Magnet

CA602-5

EAC A1 Digital 0 V When Sensing Magnet 5 V When Not Sensing Magnet

CA602-6

EAC A2 Test Approximately 7 V In Test Mode

CA602-7

EAC A2 Analog 0 - 5 V When Over Magnet

CA602-8

EAC A2 Digital 0 V When Sensing Magnet 5 V When Not Sensing Magnet

CA602-9

EAC A2 Analog 0 - 5 V When Over Magnet

CA60210

EAC B1 Analog 0 - 5 V When Over Magnet

CA60211

EAC B1 Digital 0 V When Sensing Magnet 5 V When Not Sensing Magnet

CA60212

EAC B2 Test Approximately 7 V In Test Mode

CA60213

EAC B2 Analog 0 - 5 V When Over Magnet

CA60214

EAC B2 Digital 0 V When Sensing Magnet 5 V When Not Sensing Magnet

Crown 2005 PF15116-3 Rev. 1/09

EAC Sensor

Pin 1 0 V When Sensing Magnet 5 V When Not Sensing Magnet

EAC Sensor

Pin 2 Battery Negative

EAC Sensor

Pin 3 0 V When Not In Selftest Approximately 7 V For Several Milliseconds In Self-Test

EAC Sensor

Pin 4 0 - 5 V When Over Magnet

EAC Sensor

Pin 5 +12 V

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ELECTRICAL SYSTEM Contactor

Contactor The purpose of this information is to instruct the technician on proper care and maintenance of the ED1 contactor to obtain satisfactory service from these devices. Crown has tested and applied these contactors according to the requirements of our vehicle. No modifications or changes should be made in the layout, physical arrangement or electrical connections without permission from Crown.

CAUTION Before any inspection, adjustments, servicing, parts replacement or any other act is performed requiring physical contact with the electrical working components or wiring of these contactors, disconnect battery, raise drive wheels clear of floor and place blocks under truck frame. Figure 21243

Inspection The following information is intended to assist during periods of normal maintenance and to provide checks for maintaining truck operating efficiency.

Coil

•

Remove all electrical connections.

NOTE

Contacts

•

Contacts should be replaced before the silver contact facing is completely eroded through to the backing material. The silver contact facing may transfer to the moving or stationary contact and cause buildup on one contact. This can be expected under certain conditions and does not require contact dressing or filing. It is recommended that contacts always be replaced in mating pairs.

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Before taking coil resistance reading truck should be at room temperature as heat from operation of coil can change resistance reading obtained on coil.

•

Resistance reading of the coil should be 54 Ω ± 15%.

•

If reading does not fall within the limits, replace.

•

Coil voltage is 36 or 48 V.

•

A coil suppression diode is mounted across the contactor coil to reduce noise in coil.

TSP 6000 Series

Crown 2005 PF15112-1 Rev. 1/09

ELECTRICAL SYSTEM Contactor Component Replacement Refer to Figure 21245 and parts breakdown in contactor parts of the manual when replacing ED contactor components.

Contact Replacement 1. Remove electrical connections to contacts (coils do not have to be disconnected for this procedure). 2. Remove two screws (2) from top of contacts and lift contact assembly from truck. 3. Disassemble and replace contacts Index 1 & 5. 4. Torque Index 1 to 13.4 - 14.6 Nm (9.9 - 10.8 ft lb). 5. Place contact assembly on coils and fasten securely with two screws (2). 6. Connect cables.

Coil Replacement 1. Disconnect all electrical wiring. 2. Remove four mounting screws from mounting bracket on contactor panel and remove contactor from truck. 3. Remove two screws (2) and separate contact assembly from coil assembly. 4. Select replacement coil and transfer plunger (6) from coil being replaced to replacement coil. 5. Reassemble contact assembly to coil assembly and secure with two screws (2). 6. Mount contactor on truck contactor panel and reconnect all electrical wiring.

Figure 21245

K2 Logic Power Contactor Contactor K2 provides power to control modules. The coil voltage is 48 V DC. Coil resistance is 325 Ω ± 15%. A coil suppression diode is mounted across the contactor coil to reduce noise in coil. This contactor is nonrepairable, if it fails it must be replaced as a complete unit.

Crown 2005 PF15112-2 Rev. 1/09

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ELECTRICAL SYSTEM Battery

Battery

trolyte to come in contact with eyes, skin, clothing or floor. If electrolyte comes in contact with eyes, flush immediately and thoroughly with clean water. Obtain medical attention immediately. Should electrolyte be spilled on skin, rinse promptly with clean water and wash with soap. A baking soda solution (453.6 grams (1 lb) of soda to 3.79 liters (1 gal) of water) will neutralize acid spilled on clothing, floor or any other surface. Apply solution until bubbling stops and rinse with clean water.

Care and maintenance of the battery is very important to obtain efficient truck operation and maximum battery life.

WARNING Gases produced by a battery can be explosive. • Do not smoke, use an open flame, create an arc or sparks in the vicinity of the battery. • Ventilate an enclosed area well when charging.

•

Keep vent plugs firmly in place at all times except when adding water or taking hydrometer readings.

•

Do not bring any type of flame, spark, etc., near the battery. Gas formed while the battery is charging, is highly explosive. This gas remains in the cells long after charging has stopped.

•

Do not lay metallic or conductive objects on battery. Arcing will result.

•

Do not allow dirt, cleaning solution or other foreign material to enter cells. Impurities in the electrolytes has a neutralizing effect reducing the available charge.

•

If battery repair is planned, follow the battery manufacturer's instructions concerning repair practices and procedures.

WARNING Batteries contain sulfuric acid which may cause severe burns. • Avoid contact with eyes, skin or clothing.

• •

In case of contact, flush immediately and thoroughly with clean water. Obtain medical attention when eyes are affected. A baking soda solution (453.6 grams (1 lb) of soda to 3.79 liters (1 gal) of water) applied to spilled acid until bubbling stops, neutralizes the acid for safe handling and disposal.

Leakage voltage from battery terminals to battery case can cause misleading trouble symptoms with truck electrical system. Since components of the truck electrical system are insulated from truck frame, leakage voltage will not normally affect truck operation unless a short circuit or breakdown of circuit wire insulation to truck frame occurs. A voltage check from battery connector terminal to battery case should indicate near 0 V. Typically, however, the sum of the voltages at both terminals will equal battery volts. This leakage voltage will discharge the battery. As battery cleanliness deteriorates, the usable charge of the battery decreases due to this self discharge.

Battery Care CAUTION Only qualified and experienced personnel should perform maintenance and repair on batteries.

•

Make certain the charger being used matches the voltage and amperage of the truck battery. This voltage is listed on the truck data plate.

•

Before disconnecting or connecting batteries to a charger, make sure the charger is OFF. If an attempt is made to do this while the charger is ON, serious injury to you, the battery and charger could result.

•

Never use a match or lighter. Battery fumes are explosive.

•

Make certain battery used meets weight, size and voltage requirements of truck (refer to data plate). NEVER operate truck with an undersized battery.

Although a leakage voltage reading of 0 V may not be possible, a cleaner battery will have more usable charge for truck operation and not affect operation of electronic devices on the unit.

Safety Rules •

Wear protective clothing, such as, rubber apron, gloves, boots and full-face shield when performing any maintenance on batteries. Do not allow elec-

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ELECTRICAL SYSTEM Battery Charging

Battery Installation WARNING

CAUTION

Gas formed during charging is highly explosive and can cause serious injury. • Never smoke or bring flame near the battery.

• •

Consult the charger manufacturer's manual covering your charger for operation and maintenance.

•

Battery Removal

• •

CAUTION

• • • •

•

When removing the battery, move truck to area intended for battery care. Floor must be level. Turn key switch or toggle switch to OFF position and remove key. Disconnect battery and Lockout/Tagout truck as described in Control of Hazardous Energy, Battery - Lockout/Tagout. Never move battery partially from truck without roller stand in place. Lower load engaging means completely. If battery is removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Do not allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when removing, transporting the battery. Use an insulator, such as plywood, to cover the top of the battery before and during removal.

When installing a battery, move truck to an area intended for battery care. Floor must be level. Turn key switch or toggle switch to OFF position and remove key. Lockout /Tagout truck as described in Control of Hazardous Energy, Battery - Lockout/Tagout. If battery was removed with load engaging means raised, use hoist attached to mast to provide tip over protection. Do not allow any metallic object to come in contact with the top of the battery cells. This may cause a short circuit when transporting or installing the battery. Use an insulator, such as plywood, to cover the top of the battery before and during installation.

CAUTION Make certain same battery or battery of equal weight is loaded into truck for truck stability. See data plate for minimum battery weight.

Checking Battery electrolyte level should be checked before each charge of the battery. The level should be maintained at 12.7 mm (0.5 in) above plates or just below the lower lip of the filler hole at all times. If low, add distilled water or approved local supply (consult battery manufacturer) at the end of a charge cycle. Do not overfill. For maximum battery life, specific gravity readings should be taken daily on a pilot cell and recorded. A different pilot cell should be selected on a monthly basis with readings taken on all cells at semi annual or annual intervals. Do not take specific gravity readings immediately after adding water. Water and electrolyte must be thoroughly mixed by charging before a reliable reading can be taken. Normal full charged specific gravity should be between 1.265 and 1.285.

Figure 8251

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ELECTRICAL SYSTEM Battery The battery for your turret stockpicker is located in the power unit between the mast and drive unit. The top of the battery can be exposed by raising the top tray (1) on the power unit. In order to remove the battery the battery cover (2) and retainer must be removed from the left side of truck. Refer to Figure 21262.

5. Before connecting the battery cable to the truck's receptacle, make sure key switch is OFF and all controls are in the OFF position and the brake applied. The battery cable must be fully connected before the truck is used. If the plug is not making good contact, heat will weld the two parts of the battery connector together, making it difficult to remove and necessary to replace. 6. Battery terminals should be checked and cleaned of corrosion regularly. Good battery terminal contact is essential not only for operation, but also for proper charging of the battery. 7. Battery cover should be closed except when charging. 8. Charging requirements will vary depending on truck usage. Battery should be given an equalizing charge on a weekly basis. This charge should normally be an additional three hours at the finish rate.

Charging CAUTION Figure 21262 1

Top Tray

Battery Cover

1. Charge the battery only in areas designated for that use.

When charging the battery insure the battery charger is connected to the battery and not the truck. Failure to do so may result in damage to the wire guidance system. Charging requirements will vary depending upon truck usage. A battery with a specific gravity reading of 1.160 should be recharged.

2. Make certain charger being used matches the voltage and amperage of the truck battery. This voltage is listed on the truck data plate. 3. Before disconnecting or connecting batteries to a charger, make sure charger is OFF. If an attempt is made to do this while the charger is ON, serious injury to you, the battery and charger could result. 4. Before charging, make sure battery cells contain the correct amount of water. Charging batteries with a low water level might result in damage to the cells. When checking water levels, NEVER use a match or lighter. Battery fumes are explosive.

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CAUTION Gas formed during charging is highly explosive and can cause serious injury. • Never smoke or bring flame near the battery. Consult the battery chargers manufacturer's manual covering your charger for operation and maintenance. Some of the basic rules are:

TSP 6000 Series

Crown 2005 PF15108-3 Rev. 1/09

ELECTRICAL SYSTEM Battery Placing battery on charge: 1. Park truck at charging station, lower platform and forks, turn truck OFF, chock wheels and remove key. 2. Remove battery cover and retainer from left side of truck. 3. Disconnect the battery. 4. Turn charger control to the OFF position. 5. Connect battery to charger and make sure connectors are mated all the way. 6. Set timer for specified time. Set for normal, Daily Charge, except for weekly, Equalize Charge. 7. Check ammeter to be sure it shows charge. Removing battery from charger: 1. Be sure charger is turned OFF. 2. Unplug the connector, using both hands with a straight pulling motion. 3. Properly store charger cable to prevent damage. 4. Make daily battery checks and add water as needed. 5. Connect battery to truck. Be sure connectors are mated all the way.

5. Reverse this procedure to reinstall battery into the truck.

CAUTION Make sure the same battery or battery of equal weight is loaded into truck for truck stability. See data plate for minimum battery weight.

Cleaning Always keep vent plugs securely in place when cleaning battery. When properly watered and charged, the battery will remain clean and dry. All that is necessary is to brush or blow off any dust or dirt which may accumulate on them. If electrolyte is spilled or overflows from the cell, it should be neutralized with a solution of baking soda and water (453.6 grams (1 lb) of soda to 3.79 liters (1 gal) of water). To do this, remove battery from truck, clean with solution of soda and water, brushing the soda solution to get the solution beneath the connectors and removing grime from the covers. Then rinse the battery with cool water from a low pressure supply to remove the soda and loosened dirt. If batteries stay consistently wet, they may either be overcharged or overfilled. This condition should be investigated and corrected.

6. Replace battery retainer and battery cover. Battery Removal 1. Park truck in an area set aside for battery removal that has access to a lifting device suitable to lift and remove battery from truck. 2. Lower platform and forks, turn key switch OFF, disconnect battery and chock load wheels.

CAUTION Do Not allow any metallic object to come in contact with the top of the battery, as this may cause a short circuit when battery is rolled out of the battery compartment. 3. Position battery roller stand next to truck aligned with battery. Roll battery onto roller stand which is the same height and as long, or longer than the battery. The battery now can be lifted or moved to appropriate area. 4. Inspect battery rollers and replace worn or damaged battery rollers. Verify battery spacers are in place and secure in compartment.

Crown 2005 PF15108-4 Rev. 1/09

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ELECTRICAL SYSTEM Battery Troubleshooting Records of battery specific gravity readings, charger used, truck, etc. can be the most effective troubleshooting aid. Contact your dealer for charts designed specifically for this purpose. Voltage readings of each cell taken at the normal charger finish rate also indicate battery condition. New batteries will have cell voltages ranging from 2.5 2.65 V. Older batteries may range from 2.45 - 2.55 V. These readings still indicate a battery in good condition. A variation of 0.20 V may be normal of certain cells are exposed to higher temperatures during discharge. Voltage differences that cannot be attributed to battery age or operating conditions indicate a weak cell(s) and maintenance is required.

CAUTION Only qualified and experienced personnel should perform maintenance and repair on batteries.

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ELECTRICAL SYSTEM Motor

Motor The turret stockpickers are equipped with AC motors that provide traction and hydraulic pump power. The steer motor is a DC motor. The traction motor has ECR7 sensor to monitor speed and position along with temperature sensor TS1 to monitor motor temperature. Both of these are internal in the motor. Mounted externally on the traction motor is a feedback splitter FSB. The hydraulic pump motor is either a standard performance or an optional high performance motor. Pump motor has ECR8 to monitor pump position and temperature sensor TS2 to monitor motor temperature. Both of these are internal to the motor. The steer motor is a DC motor that contains four brushes. Refer to section M6.0 for brush inspection and recommended replacement lengths.

Figure 21271

Chart 1 Motor Information Chart Traction

Hydraulic

Steer

133051

133572

133573 (High Perf.)

133789

Motor Type

AC Induction

Voltage

29.5

Rated Output Kw (HP)

7.3 (9.7)

16.2 (21.7)

0.55 (0.75)

Direction Of Rotation

Bi-Directional

CCW

Bi-Directional

Motor Diameter mm (in)

264 (10.4)

224 (8.8)

264 (10.4)

122 (4.8)

No. Of Brushes

N/A

Internal Sensors

ECR7/TS1

ECR8/TS2

N/A

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ELECTRICAL SYSTEM Event Codes

Event Codes

NOTE Your monitoring system can be accessed at three levels of authorization: • Level 1: Operator Mode

ACCESS Module Listing: ACCESS 1: Display Control Module (DCM)

• •

ACCESS 2: Hydraulic Control Module (HCM) ACCESS 3: Traction Control Module (TCM) ACCESS 4: Vehicle Control Module (VCM)

Level 2: Field Service Mode (Full Truck Operation) Level 3: Analyzer or Test Mode (No Truck Operation)

This section deals with the Level 2 and Level 3. For information on Level 1 see the Operators Manual. Refer to ACCESS 123® Chapter in the Service and Parts manual for display information.

ACCESS 5: Steering Control Module (SCM) ACCESS 6: Guidance Control Module (GCM) ACCESS 7: Accessory Control Module (ACM)

No Event Code?

ACCESS 8: Operator Control Module (OCM)

CAUTION After changing any module or updating software, check truck setups and re-calibrate, if required.

Some Troubleshooting Basics Statistically the majority of malfunctions occur in or at hardware components, contactors and motors. The next components to test are connectors, wiring and input devices such as switches, potentiometers or encoders. The last component to suspect is the motor control system. In all instances, you should begin your troubleshooting procedure at the driven device, proceed to inputs devices, then, and only then, move on to the control to which these devices attach. Note: If you need further assistance refer to your Service and Parts Manual.

WARNING

When the truck malfunctions and no event code is displayed it usually means the malfunction is Not electrical. If the truck powers up but a code is not displayed, the malfunction is probably a mechanical or hydraulic problem rather than electrical. Information regarding mechanical and hydraulic troubleshooting is located in the appropriate section of the Service and Parts manual.

To Locate Malfunctioning Components Component and Wiring Location Maps are provided at strategic locations to help you quickly determine the physical location of items in question. All components are clearly marked at the connection points.

Test Points Test points referenced in the event code descriptions are located on either the power unit or platform distribution panels.

Power Cable Connections

Never key truck ON with any control connectors disconnected. In addition, never remove or connect any control connectors while the truck is keyed ON.

When a Malfunction Occurs

•

Go to the ACCESS 1 and access the Level 2: Field Service Mode as follows.

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Crown 2006 PF15107-1 Rev. 5/09

ELECTRICAL SYSTEM Event Codes

Figure 13919-01 1

DCM - ACCESS 1 Display Control Module

ACCESS 1 Display Module (DCM)

HCM - ACCESS 2 Hydraulic Control Module

Power ON Indicator

CM - ACCESS 3 Traction Control Module

Display Screen

VCM - ACCESS 4 Vehicle Control Module

Service Required Indicator

SCM - ACCESS 5 Steering Control Module

Capacity Data Monitor

GCM - ACCESS 6 Guidance Control Module

Battery Discharge Indicator

ACM - ACCESS 7 Accessory Control Module

Enter or Return Key (used to navigate in and out of menus and to accept inputs)

OCM - ACCESS 8 Operator Control Module

Navigation Keys (used to scroll through menus)

Crown 2006 PF15107-2 Rev. 5/09

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ELECTRICAL SYSTEM Event Codes - ACCESS 1

Event Codes - ACCESS 1

•

If: Greater than 120 Ω. –

Event Code 101

•

All truck functions are disabled.

•

NOTE

Step 1: Check ACCESS 1 CAN wire #027 CA304-4 to CA106-8 and wire #022 CA304-5 to CA106-2. If: Wiring is OK and event code persists. –

•

Then proceed to Step 2.

–

If: Less then 10 kΩ. –

Then repair or replace the wiring.

Then replace RES3 or the wire harness.

Step 5: Check for CAN line short to BNEG, battery positive and truck frame. Key truck OFF and disconnect the battery. Using a DVOM, check the resistance at the power unit from CAN_L to the BNEG bus bar, CAN_L to TP8 and TP9 on the power unit distribution panel and CAN_L to truck frame. Resistance should be greater then 10 kΩ.

•

If: Wiring is bad.

Then check resistor RES3 located in the wire harness between CA703-1 and CA703-12.

If: RES3 is bad. –

Absence of BNEG to modules on the CAN bus will load the bus and impede CAN communications.

•

If: 60 Ω. –

ACCESS 1 module CAN error.

Then replace ACCESS 5.

Then repair or replace the wiring.

Step 2: Check for power to ACCESS 1, wire #207 CA304-3 to CA104-3 and wire #512 CA304-2 to CA104-6.

•

If: Wiring is OK and event code persists. –

•

Then proceed to Step 3.

If: Wiring is bad. –

Then repair or replace the wiring.

Step 3: Check for BNEG to the other modules on the CAN bus by verifying if the indicator lights are ON.

•

If: Module is without power. –

Then using a DVOM check for +B and BNEG. Should either be missing check associated wiring, connector and fuse.

Step 4: CAN communications line test:

•

–

•

Figure 13112-01

If: 0 Ω. Then a short exists between CAN_H and CAN_L. Check associated wiring, connections and fuses. Repair or replace wiring, connectors or fuses.

If: Greater than 120 Ω. –

Then a CAN bus terminating resistor may be open. Remove CA402 from ACCESS 5 and using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

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TSP 6000 Series

Figure 13547-01

Crown 2006 PF15107-3 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 1 Event Code 104

•

–

ACCESS 1 and ACCESS 4 module CAN error. All truck functions are disabled.

If: 120 Ω.

•

Then check resistor RES3 located in the wire harness between CA703-1 and CA703-12.

If: RES3 is bad.

NOTE

–

Then replace RES3 or the wire harness.

ACCESS 1 CAN bus communication with ACCESS 4 has not occurred within a specified time.

–

Key truck OFF and disconnect the battery. Using a DVOM, check the resistance at the power unit from CAN_L to the BNEG bus bar, CAN_L to TP8 and TP9 on the power unit distribution panel, and CAN_L to truck frame. Resistance should be greater then 10 kΩ.

Step 1: Key truck ON and check the status of ACCESS 4 indicator lights.

•

If: ACCESS 4 indicator lights are ON and event code persists. –

•

–

Then repair or replace the wiring.

Then check for +BV between CA314-1 and CA314-2.

If: 48 V. –

•

If: Less then 10 kΩ.

If: ACCESS 4 indictor lights are OFF. –

•

Then proceed to Step 2.

•

Then replace ACCESS 4.

If: 0 V. –

Then check wire #2950 CA314-1 to CA103-13, wire #518 CA314-2 to CA101-1, FU19 on the platform distribution panel and FU7 on the power unit distributional panel. Repair or replace as needed.

Figure 13194-01

Step 2: Check CAN communications lines. Key truck OFF and using a DVOM check the resistance between CAN_H and CAN_L resistance should be 60 Ω.

•

If: 0 Ω. –

•

Figure 13547-01

Then a short exists between CAN_H and CAN_L. Check associated wiring, connections and fuses. Repair or replace as needed.

Event Code 105

If: Greater than 120 Ω.

ACCESS 1 and ACCESS 5 module CAN error.

–

All truck functions are disabled.

Then a CAN bus terminating resistor may be open. Remove CA402 from ACCESS 5 and using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

If: Greater than 120 Ω. –

Then replace ACCESS 5.

Crown 2006 PF15107-4 Rev. 5/09

NOTE ACCESS 1 CAN bus communication with ACCESS 5 has not occurred within a specified time. Step 1: Key truck ON and check the status of ACCESS 5 indicator lights.

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ELECTRICAL SYSTEM Event Codes - ACCESS 1 •

–

•

Event Code 106

Then proceed to Step 2.

ACCESS 1 and ACCESS 6 module CAN error.

–

All truck functions are disabled.

Then check for +BV between CA403-3 and CA403-10.

NOTE

If: 48 V.

ACCESS 1 CAN bus communication with ACCESS 6 has not occurred within a specified time.

Then replace ACCESS 5.

If: 0 V. –

Then check wire #505 CA403-1 to CA406, wire #2903 CA403-10 to CA206-9, FU8 on the power unit distribution panel.

Step 1: Key truck ON and check the status of ACCESS 6 indicator lights.

•

Step 2: Check CAN communications lines. Key truck OFF and using a DVOM check the resistance between CAN_H and CAN_L resistance should be 60 Ω.

•

Then a CAN bus terminating resistor may be open. Remove CA402 from ACCESS 5, using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

•

Then replace ACCESS 5.

Key truck OFF and disconnect the battery. Using a DVOM, check the resistance at the power unit from CAN_L to BNEG bus bar, CAN_L to TP8 and TP9 on the power unit distribution panel and CAN_L to truck frame. Resistance should be greater then 10 kΩ.

If: 0 Ω. –

•

Then a CAN bus terminating resistor may be open. Remove CA402 from ACCESS 5 and using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

If: Greater than 120 Ω. –

•

Then a short exists between CAN_H and CAN_L. Check associated wiring, connections and fuses. Repair or replace as needed.

If: Greater than 60 Ω. –

Step 3: Check for CAN line short to BNEG, battery positive or the truck frame.

274

Then check wire #507 CA601-2 to CA406, wire #2905 CA601-1 to CA206-11, FU8 on the power unit distribution panel.

Step 2: Check CAN communications line.

•

Then replace RES3 or the wire harness.

M4.8-1960-006 03 Rev. 5/09

Then replace ACCESS 6.

If: 0 V. –

Then check resistor RES3 located in the wire harness between CA703-1 and CA703-12.

If: Less then 10 kΩ.

Then check for +BV between CA601-1 and CA601-2.

If: 48 V. –

•

If: RES3 is bad. –

•

If: ACCESS 6 indicator lights are OFF. –

•

Then proceed to Step 2.

Key truck OFF and using a DVOM check the resistance between CAN_H and CAN_L resistance should be 60 Ω.

If: 120 Ω. –

•

–

•

If: Greater than 120 Ω. –

•

Then a short exists between CAN_H and CAN_L. Check associated wiring, connections and fuses. Repair or replace as needed.

If: Greater than 60 Ω. –

•

If: ACCESS 6 indicator lights are ON and event code persists.

If: 0 Ω. –

•

Then repair or replace the wiring.

If: ACCESS 5 indicator lights are OFF.

–

•

–

If: ACCESS 5 indicator lights are ON and event code persists.

Then replace ACCESS 5.

If: 120 Ω.

TSP 6000 Series

Crown 2006 PF15107-5 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 1 –

•

Then check resistor RES3 located in the wire harness between CA703-1 and CA703-12.

ACCESS 1 and ACCESS 7 module CAN error.

If: RES3 is bad. –

Event Code 107

Then replace RES3 or the wire harness.

All truck functions are disabled.

Step 3: Check for a CAN line short to BNEG, battery positive or the truck frame. Key truck OFF and disconnect the battery. Using a DVOM, check the resistance at the power unit from CAN_L to the BNEG bus bar, CAN_L to TP8 and TP9 on the power unit distribution panel and CAN_L to the truck frame. Resistance should be greater then 10 kΩ.

•

NOTE ACCESS 1 CAN bus communication with ACCESS 7 has not occurred within a specified time. Step 1: Key truck ON and check the status of ACCESS 7 indicator lights.

•

If: Less then 10 kΩ.

If: ACCESS 7 indicator lights are ON and event code persists.

–

Then repair or replace wiring.

•

If: ACCESS 7 indicator lights are OFF. –

•

Then check for +BV between CA703-7 and CA703-8.

If: 48V. –

•

Then proceed to Step 2.

Then replace ACCESS 7.

If: 0V. –

Then check wire #569 CA703-8 to CA701-1, wire #2974 CA703-7 to CA701-2, FU17 on the platform distribution panel and FU8 on the power unit distribution panel.

Step 2: Check the CAN communications lines. Key truck OFF and using a DVOM check the resistance between CAN_H and CAN_L resistance should be 60 Ω.

• Figure 13640-01

If: 0 Ω. –

•

If: Greater than 60 Ω. –

Figure 13547-01

•

Then a CAN bus terminating resistor may be open. Remove CA402 from ACCESS 5, using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

If: Greater than 120 Ω. –

Crown 2006 PF15107-6 Rev. 5/09

Then a short exists between CAN_H and CAN_L. Check associated wiring, connections and fuses. Repair or replace as needed.

TSP 6000 Series

Then replace ACCESS 5.

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ELECTRICAL SYSTEM Event Codes - ACCESS 1 •

–

•

–

If: 120 Ω. Then check resistor RES3 located in the wire harness between CA703-1 and CA703-12.

•

–

•

Then replace RES3 or the wire harness.

Step 3: Check for a CAN line short to BNEG, battery positive or the truck frame. Key truck OFF and disconnect the battery. Using a DVOM, check resistance at the power unit from CAN_L to the BNEG bus bar, CAN_L to TP8 and TP9 on the power unit distribution panel and CAN_L to truck frame. Resistance should be greater then 10 kΩ.

•

If: Less then 10 kΩ. –

If: 48 V. –

If: RES3 is bad.

Then replace ACCESS 8.

If: 0 V. –

Then check wire #520 CA504-2 to CA505-1, wire #2995 CA504-1 to CA318-6, FU18 on the platform distribution panel and FU7 on the power unit distribution panel.

Step 2: Check CAN communications lines. Key truck OFF and using a DVOM check the resistance between CAN_H and CAN_L should be 60 Ω.

•

Then repair or replace the wiring.

If: 0 Ω. –

•

Then check resistor RES3 located in the wire harness between CA703-1 and CA703-12.

If: RES3 is bad. –

ACCESS 1 and ACCESS 8 module CAN error.

Then replace ACCESS 5.

If: 120 Ω. –

Figure 13641-01

Then a CAN bus terminating resistor may be open. Remove CA402 from ACCESS 5, using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

If: Greater than 120 Ω. –

•

Then a short exists between CAN_H and CAN_L. Check associated wiring, connections and fuses. Repair or replace as needed.

If: Greater than 120 Ω. –

Event Code 108

Then check for +BV between CA504-1 and CA504-2.

Then replace RES3 or the wire harness.

All truck functions are disabled.

Step 3: Check for a CAN line short to BNEG, battery positive or the truck frame.

NOTE

ACCESS 1 CAN bus communication with ACCESS 8 has not occurred within a specified time. Step 1: Key truck ON, check the status of ACCESS 8 indicator lights.

•

If: ACCESS 8 indicator lights are ON and event code persists. –

•

If: Less then 10 kΩ. –

Then repair or replace wiring.

Then proceed to Step 2.

If: ACCESS 8 indicator lights are OFF.

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TSP 6000 Series

Crown 2006 PF15107-7 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 1 Event Code 115 ACCESS 5 module software not compatible with the other modules. All functions are disabled. Step 1: Install ACCESS 5 with compatible software or load present ACCESS 5 with compatible software. Figure 13642-01

Event Code 116 ACCESS 6 module software not compatible with the other modules. All functions are disabled. Step 1: Install ACCESS 6 with compatible software or load present ACCESS 6 with compatible software. Figure 13547-01

Event Code 112 ACCESS 2 module software not compatible with the other modules. All functions are disabled. Step 1: Install ACCESS 2 with compatible software or load present ACCESS 2 with compatible software.

Event Code 113 ACCESS 3 module software not compatible with the other modules. All functions are disabled. Step 1: Install ACCESS 3 with compatible software or load present ACCESS 3 with compatible software.

Event Code 117 ACCESS 7 module software not compatible with the other modules. All functions are disabled. Step 1: Install ACCESS 7 with compatible software or load present ACCESS 7 with compatible software.

Event Code 118 ACCESS 8 module software not compatible with the other modules. All functions are disabled. Step 1: Install ACCESS 8 with compatible software or load present ACCESS 8 with compatible software.

Event Code 114 ACCESS 4 module software not compatible with the other modules. All functions are disabled. Step 1: Install ACCESS 4 with compatible software or load present ACCESS 4 with compatible software.

Crown 2006 PF15107-8 Rev. 5/09

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ELECTRICAL SYSTEM Event Codes - ACCESS 2

Event Codes - ACCESS 2

Step 1: Using a DVOM check the hydraulic pump motor windings for a short to truck frame.

Event Code 212

•

If: Winding(s) are shorted. –

ACCESS 2 module current out of range. Main raise, auxiliary raise, traverse, pivot, fork extend or retract are disabled.

•

Then replace the motor.

If: Winding(s) are OK and event code persists. –

Then replace ACCESS 2.

NOTE

Event code is logged when a higher than normal current is sensed at ACCESS 2, terminals U, V, or W. Possible cause, shorted power cables or motor windings.

If event code persists after replacing ACCESS 2 a phase to phase motor short may exist. Motor exchange is required to test for this condition.

Step 1: Using a DVOM check the power cables U, V, W for shorts to truck frame.

Event Code 214

•

ACCESS 2 module precharge error.

If: Cables are shorted. –

•

Main raise, auxiliary raise, traverse, pivot, fork extend or retract are disabled.

Then repair or replace cables.

If: Cables are OK. –

Step 1: Load default parameters and configure as required.

Then proceed to Step 2.

Step 2: Using a DVOM check the hydraulic pump motor windings for a short to truck frame.

Event Code 215

•

If: Winding(s) are shorted.

ACCESS 2 module below operating temperature.

–

Main raise, auxiliary raise, traverse, pivot, fork extend or retract are disabled.

•

Then replace the motor.

If: Winding(s) are OK and event code persists. –

Then replace ACCESS 2.

NOTE If event code persists after replacing ACCESS 2 a phase to phase motor short may exist. Motor exchange is required to test for this condition.

If: ACCESS 2 is warm and event code persists. Then replace ACCESS 2.

Event Code 216

ACCESS 2 module current sensor error. Main raise, auxiliary raise, traverse, pivot, fork extend or retract are disabled.

NOTE Event is logged if an invalid current offset is detected by ACCESS 2 current sensors.

278

•

–

Event Code 213

M4.8-1960-010 03 Rev. 5/09

Step 1: Event code is logged if internal ACCESS 2 temperature is below -40 °C (-40 °F). This may occur as a result of parking the truck with the key OFF in 40 °C (-40 °F) for an extended period of time. Move truck to a warm area, when ACCESS 2 temperature has risen key truck ON.

ACCESS 2 module above operating temperature. Main raise, auxiliary raise, traverse, pivot, fork extend or retract are disabled. Step 1: Event is logged if internal ACCESS 2 temperature exceeds 95 °C (203 °F). As temperature increases event code 222 will be logged when ACCESS 2 temperature exceeds 85 °C (185 °F).

TSP 6000 Series

Crown 2006 PF15107-9 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 2 When event code 222 is logged ACCESS 2 performance will be limited until the temperature lowers. Allow the truck to cool and inspect ACCESS 2 mounting bolts.

•

If: After cooling, the hydraulic system operates at normal performance levels. –

•

Then truck is operation ready.

If: After cooling event codes 216 and 222 persists. –

Then replace ACCESS 2.

Main raise, auxiliary raise, traverse, pivot, fork extend or retract are disabled.

If: Correct battery.

•

If: 48 to 52 V.

•

Then charge or replace the battery.

• •

•

Then battery is OK, proceed to Step 3.

If: +BV below or above voltage range. –

Then charge or replace the battery.

If: Loose connections. –

•

Then tighten the connections.

If: Connections are tight and event code persists. Then replace ACCESS 2.

Then replace ACCESS 2.

ACCESS 2 module low temperature cutback. Hydraulic performance is reduced. Step 1: Event code is logged if internal ACCESS 2 temperature is below -25 °C (-13 °F). This may occur as a result of parking the truck with the key OFF in 25 °C (-13 °F) for an extended period of time. Key truck ON and operate as internal ACCESS 2 temperature rises hydraulic performance will return.

•

If: +BV out of range.

If: Hydraulic performance does not return and event code persists.

–

Then check FU12.

If: FU12 is bad. –

•

Then using a DVOM check for +BV between ACCESS 2 +B and BNEG terminals.

If: +BV present and event code persists. –

–

Event Code 221

If: ED contacts pull-in. –

Then proceed to Step 2.

If: 48 to 52 V.

–

Step 3: Verify the operation of ED1 and ED2 (ED2 if present).

•

If: Correct battery. –

Then battery is OK, proceed to Step 3.

If: +BV below or above voltage range. –

•

Then proceed to Step 2.

Step 2: Using a DVOM check the battery voltage.

–

Step 1: Check for the correct battery.

Step 3: Check power cable connections. ACCESS 2 BNEG and +B and the hydraulic pump motor U, V, W.

Step 1: Check for the correct battery.

•

Main raise, auxiliary raise, traverse, pivot, fork extend or retract are disabled.

•

ACCESS 2 module battery voltage out of range.

–

ACCESS 2 module battery voltage out of range.

Step 2: Using a DVOM check the battery voltage.

Event Code 217

•

Event Code 218

Event Code 222

Then replace FU12.

ACCESS 2 module high temperature cutback.

If: FU12 is good. –

Then check ACCESS 2 power cable connections.

Crown 2006 PF15107-10 Rev. 5/09

Then replace ACCESS 2.

Hydraulic performance reduced. Step 1: Event code is logged if ACCESS 2 base plate temperature exceeds 85 °C (185 °F). Possible cause

TSP 6000 Series

M4.8-1960-012 03 Rev. 5/09

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ELECTRICAL SYSTEM Event Codes - ACCESS 2 –

of excessive ambient temperature or load on hydraulic system or improper mounting of ACCESS 2. Allow hydraulic system to cool then key truck ON.

•

If: Hydraulic system operates at set performance level. –

•

Then truck is operation ready.

No action taken.

Then replace ACCESS 2.

NOTE

Event Code 223

Event code 224 could log as the result of other event codes. Check for other event codes and resolve them before proceeding with this event code 224. Event code is logged if voltage at ACCESS 2, +B terminal is too high. This could occur if regenerative braking current is high enough to elevate the battery voltage during regen braking.

ACCESS 2 module under voltage cutback. Hydraulic performance is reduced.

NOTE Event code 223 could log as the result of other events. Check for other event codes and resolve them before proceeding with event code 223. Step 1: Event code is logged when voltage at ACCESS 2 +B terminal is low. Check for correct battery.

•

If: Correct battery. –

If: 48 to 52 V. –

•

Then proceed to Step 3.

If: ED1 (ED2 if present) pull in. –

•

If: 48 to 52 V and event code persists. –

•

Then check the battery voltage between ACCESS 2 +B and BNEG terminals.

Then replace ACCESS 2.

If: Less than 48 to 52 V.

If: Correct battery. –

Then proceed to Step 2.

Step 2: Disconnect the battery and using a DVOM, check for +BV at the connector (battery should be between 48 to 52 V). –

•

Then proceed to Step 3.

If: +BV above voltage range –

•

Then charge or replace the battery.

Step 3: Check operation of ED1 and ED2 (if present).

•

Then replace the battery.

Step 3: Check the power cable on ACCESS 2, +B and BNEG terminals also U, V and W connections on ACCESS 2 and the hydraulic pump motor.

If: +BV below voltage range. –

Step 1: Check for the correct battery.

If: 48 to 52 V.

Then proceed to Step 2.

Step 2: Disconnect the battery and using a DVOM, check for +BV at the connector (battery should be between 48 to 52 V).

•

Event Code 224 ACCESS 2 module overvoltage cutback.

If: ACCESS 2 is cool and event code persists. –

Then check FU12, power cable connections between battery, ED1 (ED2 if present) and ACCESS 2.

If: Connections are loose. –

•

Then tighten the connections.

If: Connections are OK and event code persists. –

Then replace ACCESS 2.

Event Code 225 ACCESS 2 module 5V supply out of range. Main raise, main lower, auxiliary raise limp mode. Step 1: Using a DVOM connect the positive meter lead to CA411-26 and the negative lead to BNEG. Key truck ON and check the voltage.

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TSP 6000 Series

Crown 2006 PF15107-11 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 2 •

–

•

Step 1: Event code is logged when the motor temperature exceeds a preset limit. Temperature is monitored through sensor TS2 located in M2. Key truck OFF and allow system to cool then key truck ON.

•

If: Hydraulic system operates at set performance level. –

•

Then replace M2.

If: Event code persists. –

Then replace ECR8.

Then truck is operation ready.

If: M2 is cool and event code persists. –

Then repair or replace the wiring.

If: Event code persists. –

Temperature is monitored through sensor (TS2) located in M2.

•

If: Wiring is OK. –

•

Then a short exists in either the wiring to ECR8 or ECR8 itself is shorted. Check wire #708 CA411-26 to CA415-1, RED wire between CA415-1 and ECR8, wire #025 CA411-31 to CA415-3, WHT wire between CA415-3 and ECR8, wire #026 CA411-32 to CA415-4, BLU wire CA415-4 to ECR8.

If: Wiring is bad. –

•

Then remove wire #708 from CA411-26. Check the voltage between CA411-26 and BNEG.

If: 4.5 to 5.5 V. –

•

NOTE

If: Not 4.5 to 5.5 V.

Then replace ACCESS 2.

Event Code 229

Then replace ACCESS 2. ACCESS 2 hydraulic pump motor M2 temperature sensor TS2 error. Main raise, main Lower, auxiliary raise limp mode. Step 1: Event code is logged when the motor temperature exceeds a preset limit. Temperature is monitored through sensor TS2 located in M2. Key truck OFF and allow system to cool then key truck ON.

•

If: Hydraulic system operates at set performance level. –

•

If: Event code persists. –

• Figure 13193-01

Event Code 228 ACCESS 2 module hydraulic pump motor (M2) high temperature cutback.

Then key truck OFF and check wire #102 CA411-8 to CA415-6, WHT wire CA415-6 to TS2, wire #526 CA411-7 to wire #594 CA415-5, BLK wire CA415-5 to TS2.

If: Wiring is bad. –

•

Then truck is operation ready.

Then repair or replace the wiring.

If: Wiring is OK and event code persists. –

Then replace M2.

Hydraulic performance is reduced.

Crown 2006 PF15107-12 Rev. 5/09

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ELECTRICAL SYSTEM Event Codes - ACCESS 2 •

If: FAN3 is running then a short to BNEG exists. –

Then refer to the BNEG test.

Step 2: Connect the DVOM leads across FAN3 terminals (wires connected). Key truck ON while pressing the up and down arrow keys, select FAN3 A4.4.13 on menu. Press and hold the enter key (turns ON driver).

•

If: +BV, but fan does not run. –

•

If: 0 V. –

Figure 13193-01

If: +BV. –

ACCESS 2 module high performance hydraulics fan driver shorted or open. No action taken.

•

Verify that the problem still exists, key truck ON while pressing the up and down arrow keys.

•

If: Setup is wrong. Then correct setup.

Then proceed to Step 2.

Key truck ON while pressing the up and down arrow keys.

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Then key truck OFF and remove wire #5997 from CA411-6. Connect the DVOM leads across FAN3, key truck ON while pressing the up and down arrow keys.

If: 0 V. –

Then a short is in ACCESS 2. Replace ACCESS 2.

If: Greater than 1 V. –

If: Setup is correct and event code persists. –

If: FAN3 runs continuously. –

Step 1: Check F15 in the features menu. Verify that standard performance is selected for standard trucks or high performance is selected for high performance trucks.

•

Then replace ACCESS 2.

Short to BNEG test:

Event code is logged under the following condition(s). • Open FAN3 or wiring preventing current flow when FAN3 driver is requested. • Short between +B and CA411-6. Could be FAN3 or wiring. • Short between BNEG and CA411-6. Could be internal or external of ACCESS 2, will log at key ON.

–

Then an open exists between FAN3 and ACCESS 2. Check wire #5997 and SB41.

If: 0 V. –

NOTE

Then a positive or negative is missing. Proceed to Step 3.

Step 3: Check wire #29121 CA411-13 to verify continuity check for an open circuit. Connect the DVOM leads between wire #5997 at CA411-6 and the negative terminal of FAN3. Key truck ON while pressing the up and down arrow keys, select FAN3 A4.4.13 on menu. Press and hold the enter key (turns ON driver).

•

Event Code 231

Then FAN3 is open. Replace FAN3.

Then a short is in the wire. Replace wire #5997.

Step 4: Check wires for cuts in insulation or shorts to truck frame. Check wire #29121 FAN3 to CA411-13, wire #5997 CA411-6 to SB41, and SB41 lead wires. If problem persists, then FAN3 is shorted. Replace FAN3.

TSP 6000 Series

Crown 2006 PF15107-13 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 2 •

Then a short in truck wiring exists. Check the wiring between ACCESS 2 and HN.

•

If: HN sounds continuously when truck is turned ON. –

•

Then a short to BNEG exists. Verify the problem still exists by keying truck ON. If HN is ON continuously, disconnect wire #5928 from HN. Connect a DVOM between wire #5928 and HN +B terminal.

If: 0 V. –

Figure 13236-01

Then a short circuit is internal to ACCESS 2. Reconnect wire #5928 and replace ACCESS 2.

Event Code 232 ACCESS 2 module horn (HN) driver shorted or open. Traction limp mode (travel limited to 1.6 km/h (1.0 mph or less). Step 1: Key truck ON.

•

If: Wrench light illuminates and event code 232 is logged.

•

Then either a short to BNEG or an open exists.

•

If: HN fails to function, wrench light does not illuminate and event code 232 is not logged.

•

Then press HN button for at least 3 seconds.

•

If: Wrench light illuminates and event code 232 is logged when HN button is pressed.

•

Then a short to +B exists. Verify the problem still exists by pressing the HN button, if wrench illuminates when the HN button is pressed and goes off when the HN button is released then the problem still exists. Remove wire #5928 from the HN terminal and key truck ON.

•

If: Wrench illuminates and event code 232 is logged.

•

Then the short is in ACCESS 2. Reconnect wire #5928 and replace ACCESS 2.

•

Figure 13612-01

Event Code 233 ACCESS 2 module SVML driver shorted or open. Driver Shorted: Main raise, main lower and auxiliary raise in limp mode. Driver Open: Main lower is disabled.

If: Wrench light does not illuminate but event code 232 is logged when HN button is pressed.

Crown 2006 PF15107-14 Rev. 5/09

TSP 6000 Series

M4.8-1960-016 03 Rev. 5/09

283

ELECTRICAL SYSTEM Event Codes - ACCESS 2 NOTE Event code is logged under the following condition(s). • Open in SVML coil or wiring. Prevents current flow when SVML driver is requested. • Short to +B. Possible cause; shorted SVML coil or a short in the wiring between SVML and ACCESS 2. • Short to BNEG. Supplies voltage to SVML when key is turned ON. Possible cause; a short in the wiring ACCESS 2.

•

Then raise the main mast 305 mm (12.0 in) and attempt to lower. Check for event code.

•

–

•

If: 0 V. –

•

Then a short exists in either the truck wiring or ACCESS 2. Check the wiring between SVML and ACCESS 2. If no shorted wire is found then replace ACCESS 2.

Then replace SVML.

If: Resistance is between 20 and 40 Ω. –

Then proceed with step 3.

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Then a proceed to step 4.

Step 4: Connect the DVOM negative lead to BNEG and positive lead to SVML terminal with the GRN/WHT wire, leave the wires connected. Select SVML (A4.4.4) in the display menu. Press and hold the enter key (drives SVML). Check the meter reading.

•

Then a positive is missing. Check wire #2927 CA414-1 to SVML, wire #2958 to CA406, wire #2914/#29121 CA411-13 to CA406.

If: +BV. –

Then the negative is missing. Check the negative output by connecting a DVOM between the SVML terminal with the GRN/WHT wire and CA411-4. Key truck ON while pressing the up and down arrows. Select SVML (A4.4.4) on the display menu and press and hold the enter key (drives SVML), check the meter reading.

–

If: +BV.

–

Then an open exists between ACCESS 2 and SVML, check the wiring connections.

If: 0 V. –

If: Resistance not between 20 and 40 Ω. –

Then a short exists in the wiring, check the wiring.

If: Wiring is OK and event persists.

Then a short exists in SVML, replace SVML.

Step 2: Remove wires #5911 and #2927/#2936 from SVML. Using a DVOM check the resistance of the SVML coil.

Then a short exists inside of ACCESS 2, replace ACCESS 2.

If: Voltage greater than 1 V.

If: Wrench light does not illuminate but event code 233 is logged whenever attempting a main lower. –

•

–

•

Then a short to BNEG exists, remove wire #5906 from CA411-4 and key truck ON.

If: 0 V.

Then a short to +B exists, remove wire #5911 from terminal on SVML and key truck ON.

If: Wrench light illuminates and stays ON and event code 233 is logged. –

•

Then either a short circuit to BNEG or a short to frame exists, follow steps 2 through 4.

If: Performing a main lower illuminates the wrench light and logs event code 233 but when main lower is stopped wrench light clears. –

•

–

If: After power up wrench light does not illuminate and event code 233 is not logged. –

If: Voltage greater than 1V. –

If: After power up wrench light illuminates and event code 233 is logged. –

•

Step 1: Key truck ON.

•

Step 3: Reconnect the wires to SVML. Key truck ON and using a DVOM check the voltage across the SVML terminals.

Then an open exists in ACCESS 2, replace ACCESS 2.

If: Approximately 24 V for 3 seconds and then drops to 0 V. –

TSP 6000 Series

Then this is a correct functional reading. Problem may be an intermittent connection. Check wiring and connections. Crown 2006 PF15107-15 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 2 •

If: Resistance is OK. –

Then proceed with step 2.

Step 2: Reconnect wires #5910, #2936 and #29107 to SP1. Connect one meter lead to BNEG and the other to SP1 terminal with RED/WHT wire #2936. Key Truck ON and check the meter reading.

•

If: Not battery voltage. –

Then an open exists between RED/WHT wire from SP1 to ACCESS 2, CA411-13. Repair or replace the wire.

–

If: Battery voltage.

–

Then proceed to Step 3.

Step 3: Connect the DVOM leads across SP1 terminals. Key truck ON while pressing the up and down arrow keys, select SP1 A4.4.3 on the display menu. Press and hold the enter key (drives SP1), check the meter reading.

•

If: 0 V. –

Then the negative is missing. Check the negative output with the DVOM between SP1 terminal with GRN/WHT wire and CA411-3. Key truck ON while pressing the up and down arrow keys, select SP1 A4.4.3 on the display menu. Press and hold the enter key (drives SP1), check the meter reading.

–

If: 24 V for 3 seconds and then drops to 0 V.

–

Then this is a correct functional reading. Problem may be an intermittent connection. Check the wiring.

Figure 13612-01

Event Code 234 ACCESS 2 module SP1 driver shorted or open. Driver Shorted: Main raise, main lower and auxiliary raise in limp mode. Driver Open: Main lower is disabled.

NOTE

•

Event code is logged under the following condition(s). • Open coil or wiring prevents current flow when SP1 driver is requested. • Short to +B. Possible cause: shorted SP1 coil or short in wiring between SP1 and ACCESS 2. • Short to BNEG. Supplies voltage to SP1. Possible cause a short in wiring or ACCESS 2. Step 1: Remove wires #5910, #2936 and #29107 from SP1. Using a DVOM check the resistance of SP1 coil.

•

If: Between 20 to 40 Ω.

•

If: SP1 coil out of range. –

Then replace SP1.

Crown 2006 PF15107-16 Rev. 5/09

If: Battery voltage. –

•

If: Greater than 1 V. –

•

Then a short to BNEG exists. Connect the DVOM across the SP1 coil terminals, key truck ON, check the meter reading.

Then a short exists, disconnect wire #5904 from CA411-3 and key truck ON.

If: Voltage is greater than 1 V. –

Then a short exists in the wiring between SP1 and ACCESS 2, check the wiring.

–

If: 0 V.

–

Then a short exists in ACCESS 2, replace ACCESS 2.

TSP 6000 Series

M4.8-1960-020 03 Rev. 5/09

285

ELECTRICAL SYSTEM Event Codes - ACCESS 2 •

If: After power up wrench light does not illuminate and event code 235 is not logged. –

•

If: Performing the main raise the illuminates the wrench light and logs event code 235 but when raise control is stopped wrench light clears. –

•

Then a short exists in either the truck wiring or ACCESS 2. Check wiring between PVMR and ACCESS 2.

If: Wiring is OK. –

Figure 13612-01

Then a short exists in PVMR, replace PVMR.

If: Wrench light does not illuminate but event code 235 is logged when attempting a main raise. –

•

Then a short to +B exists. Remove wire #5990 from PVMR terminal. Key truck ON.

If: Wrench light illuminates and event code 235 is logged. –

•

Then raise the main mast 305 mm (12.0 in) and check for event code.

Then replace ACCESS 2.

Event Code 235

Step 2: Disconnect wires #5990 and #29107 from PVMR. Using a DVOM check the resistance of PVMR coil.

ACCESS 2 module PVMR driver shorted or open.

•

Main raise disabled. Main lower and auxiliary raise in limp mode.

–

•

Event code is logged under the following condition(s). • Open PVMR coil or wiring preventing current flow when PVMR driver is requested. • Short to +B. Possible cause; defective PVMR or a short in the wiring to PVMR or ACCESS 2. • Short to BNEG. Supplies voltage to PVMR coil when key is turned ON. Possible cause; a short in the wiring or ACCESS 2.

•

If: Wrench light illuminates and event code 235 is logged. –

Then either a short to BNEG or an open exists. Follow steps 2 through 5.

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Then proceed to step 3.

Step 3: Reconnect wires to PVMR. Connect the DVOM leads across PVMR terminals and key truck ON. Check the meter reading

•

If: Greater than 1 V. –

• •

Then a short to BNEG exists. Key truck OFF and remove wire #5976 from CA411-2 and key truck ON.

If: Greater than 1 V. –

Step 1: Key truck ON.

Then replace PVMR.

If: Resistance is OK. –

NOTE

•

If: Not between 20 to 40 Ω.

Then a short exists. Check the wiring.

If: Wiring is OK. –

Then an internal short exists in ACCESS 2, replace ACCESS 2.

Step 4: Connect the DVOM negative lead to BNEG and the positive lead to PVMR terminal with the GRN/

TSP 6000 Series

Crown 2006 PF15107-17 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 2 WHT wire. Select A4.4.2 on the display menu. Press and hold the enter key (drives component). Check the meter reading.

•

If: 0 V. –

•

If: +BV. –

•

Then the positive is missing. Check wire #29107 PVMR to SP1, wire #2936 SP1 to SVML, wire #2927 CA414-1 to SVML, wire #2958 to CA406, wire #2914/#29121 CA411-13 to CA406.

Then the negative is missing, check the wiring.

If: Reading is approximately 24 V for 3 seconds then drops to 0 V. –

Then this is a correct functional reading. Problem may be an intermittent or loose connection. Check the wiring and connections.

NOTE Event code 236 could be the result of other events. If other event codes have been logged resolve them before proceeding with event code 236. Step 1: Check the wiring for a short or an open condition. RED, BLK, WHT, BLU wires between CA415 and ECR8, wire #708 CA411-26 to CA415-1, wire #526 CA411-7 to wires #593/#594, wire #593 to CA415-2, wire #025 CA411-31 to CA415-3 and wire #026 CA411-32 to CA415-4.

•

If: Wiring is OK and event code persists. –

•

Then replace ECR8.

If: Event code persists after replacing ECR8. –

Then replace ACCESS 2.

Figure 13193-01

Event Code 237 Pump motor open (M2). Figure 13612-01

Main raise, auxiliary raise, traverse, pivot, fork extend or retract are disabled.

Event Code 236

NOTE

ACCESS 2 module hydraulic pump motor feedback encoder (ECR8) count out of tolerance. All hydraulic functions in limp mode.

Crown 2006 PF15107-18 Rev. 5/09

Event code logged if the pump motor (M2) is open. Step 1: Check continuity of M2 phase cables from ACCESS 2 terminals to corresponding M2 terminals.

TSP 6000 Series

M4.8-1960-023 03 Rev. 5/09

287

ELECTRICAL SYSTEM Event Codes - ACCESS 2 •

If: Connection is open. –

•

If: All three cables are OK. –

•

Then check the continuity at M2 terminals U V, V - W and W - U.

If: Any terminals read open. –

•

Then repair or replace cable or connections.

•

If: Event code persists after download. –

Then replace ACCESS 2.

Event Code 255 ACCESS 2 Main Chain Slack.

Then replace M2.

Main or auxiliary lower, traction, pivot, traverse and fork extend or retract are disabled.

If: All read OK. –

Step 1: Module may be programmed incorrectly, download software.

Then replace ACCESS 2.

Step 1: Key truck ON and perform the main raise function.

Event Code 246

•

ACCESS 2 module defaults not loaded.

If: Wrench light is OFF all functions are now enabled. –

All hydraulic functions are disabled. Step 1: Replace ACCESS 2 or download default parameters to existing module.

•

If: Chain slack condition still exists. –

Event Code 247 ACCESS 2 module internal fault. All hydraulic functions except auxiliary lower are disabled.

•

Then: Chain slack condition has been corrected.

Then: Key truck ON while depressing the up arrow. Select Analyzer Mode and scroll to A2.2.15 to view CHS5 and CHS6 switch condition.

If: CHS5 or CHS6 chain slack switch(es) are open –

Then: Check chain and switch adjustments.

Step 1: Module may be programmed incorrectly, download software.

•

If: Event code persists after download. –

Then replace ACCESS 2.

Event Code 249 ACCESS 2 module parameter change error. All hydraulic functions are disabled. Step 1: Key truck OFF then ON.

•

If: Event code persists. –

Then replace ACCESS 2.

Figure 21210

Event Code 251

Event Code 256

ACCESS 2 module general fault.

ACCESS 2 Main Chain Break.

All hydraulic functions are disabled.

Main, auxiliary raise, lower, traction, pivot, traverse and fork extend, retract are disabled.

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288

TSP 6000 Series

Crown 2006 PF15107-19 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 2 –

Step1: Check the condition of the mast chains.

•

If: Chains are OK. –

Then proceed to Step 2.

•

Step 2: Key truck ON while pressing the up arrow key. Select Analyzer Mode scroll to A2.2.16 to view CHS7 and CHS8 switch condition.

•

If: CHS7 or CHS8 chain break switches are open. –

If: 5 V. –

•

Then disconnect wire #708 at CA415-1 and check the voltage between wire #708 and BNEG.

Then replace ECR8.

If: Less than 5 V. –

Then replace ACCESS 2.

Then check chain routing, mast and platform hardware.

Event Code 268 ACCESS 2 module internal fault. Main raise, auxiliary raise, traverse, pivot and fork extend are disabled. Main lower in limp mode. Step 1: Replace ACCESS 2.

Event Code 269 ACCESS 2 module 5 V power supply out of range. Main raise, main lower, auxiliary raise are in limp mode. Figure 13193-01

Step 1: Connect the DVOM negative lead to BNEG and positive lead to CA411-26. Key truck ON and check the meter.

Event Code 272

•

ACCESS 2 module CAN timeout.

If: 5 V (± 0.5 V) and event code 269 is logged. –

• •

All hydraulic functions except auxiliary lower are disabled.

If: 5 V (± 0.5 V) and event code 269 is logged.

Step 1: Event code is displayed and flashed.

–

•

Then replace ECR8.

If: 0 V. –

•

Then move the DVOM positive lead to CA415-1.

If: Event code 407 is displayed for ACCESS 1 and event code 272 is flashed on ACCESS 2. –

Then check CAN wires #023 and #024 between ACCESS 2 CA411-23, -35 and the power unit distribution panel CA201-4 and -10. Verify CAN_H and CAN_L wires are not reversed. Check the resistance between CAN_H and CAN_L lines, resistance should be approximately 60 Ω. Check for shorts or loss of terminating resistors. The CAN bus contains two terminating resistors, one located in the ACCESS 5 module and the other in the wire harness between CA703-12 and CA701-8.

TSP 6000 Series

M4.8-1960-026 03 Rev. 5/09

Then an open exists between ACCESS 2 and ECR8. Check the RED, BLK, WHT, BLU wires between CA415 and ECR8, wire #708 CA411-26 to CA415-1, wire #526 CA411-7 to wires #593, #594, wire #593 to CA415-2, wire #025 CA411-31 to CA415-3 and wire #026 CA411-32 to CA415-4.

If: Less than 5 V.

Crown 2006 PF15107-20 Rev. 5/09

289

ELECTRICAL SYSTEM Event Codes - ACCESS 2 •

If: Event codes 504, 701, or 803 are displayed on ACCESS 1 and event code 272 is flashed on ACCESS 2. –

Then check CAN wires #028 and #029 between ACCESS 4 CA314-3, -4 and the platform distribution panel CA106-1, -9.

Step 1: Check wiring for a short or an open condition. RED, BLK, WHT, BLU wires between CA415 and ECR8, wire #708 CA411-26 to CA415-1, wire #526 CA411-7 to wires #593, #594, wire #593 to CA415-2, wire #025 CA411-31 to CA415-3 and wire #026 CA411-32 to CA415-4.

•

If: Wiring is OK and event code persists. –

Then replace ECR8.

Figure 13547-01

Figure 13550-01 Figure 13193-01

Event Code 278 ACCESS 2 module internal fault. All hydraulic functions except auxiliary lower are disabled. Step 1: Replace ACCESS 2. Figure 13552-01

Event Code 273 ACCESS 2 module ECR8 hydraulic pump motor (M2) encoder count out of range. All hydraulic functions in limp mode.

NOTE Event code 273 could be the result of other event codes. If other event codes have been logged resolve them before proceeding with event code 273.

M4.8-1960-028 03 Rev. 5/09

290

TSP 6000 Series

Crown 2006 PF15107-21 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 3

Event Codes - ACCESS 3

Event Code 313

Event Code 300

ACCESS 3 module traction motor (M1) current sensor fault.

ACCESS 3 module pre-charge timeout or failure to follow ACCESS 5 module ED1 and ED2 (if present) command. Traction is disabled.

Traction is disabled. Step 1: Check the motor phase cabling for a short to motor or the truck frame.

•

Step 1: Determine the current status of event codes 546, 547, and 548.

•

Then follow the procedure for event code 546.

If: None of the above event codes have been logged. –

•

ACCESS 3 module heat sink temperature less than -40 °C (-40 °F).

If: Short circuit exists between U, V, W cables or frame.

•

Traction is disabled. Step 1: Determine the ambient temperature of the environment.

•

Then remove phase cabling and check for shorts directly on M1.

If: Short exists in M1 windings.

If: Ambient temperature is below -40 °C (-40 °F) and truck has set idle for an extended time. –

•

Then replace M1.

Then check for a short in the phase cabling.

Then ACCESS 3 heat sink must be warmed to operate.

If: Ambient temperature is above -40 °C (-40 °F) and event code persists. –

If: No short exists in M1 windings. –

Then replace ACCESS 3.

Event Code 315

Step 1: Disconnect traction motor (M1) phase cabling from ACCESS 3. Check M1 and cabling for phase-tophase and phase-to-frame short circuit.

•

Then fault is in the phase cabling and frame, repair as needed.

If: No shorts exist and the event code persists. –

Traction is disabled.

–

Then replace M1.

If: No motor winding short exists. –

Then replace ACCESS 3.

ACCESS 3 module over current condition.

•

Then remove the phase cabling and check for motor winding short to motor or truck frame.

If: Motor windings are shorted. –

•

Event Code 312

–

•

Then follow procedure for event code 503 to check for CAN bus failures.

If: Event code persists. –

•

–

If: Above event codes have been logged. –

•

If: Short circuit exists between U, V, W cables and truck or the motor frame.

Then replace ACCESS 3.

Event Code 317 and 318

If: No short circuits exist in the phase cabling and the event code persists.

ACCESS 3 module +BV under or over range.

–

Procedures listed apply to Event Codes 317 and 318.

Then replace ACCESS 3.

Traction is disabled.

Crown 2006 PF15107-22 Rev. 5/09

TSP 6000 Series

M4.8-1960-029 03 Rev. 5/09

291

ELECTRICAL SYSTEM Event Codes - ACCESS 3 NOTE If: Occurs with event code indicating ED system issue. Then refer to ED system event code 541 first. Step 1: Check the feature menu for proper battery configuration.

•

–

•

Then charge or change the battery.

Then check the cable connections between ED1 and ED2 (if present) and FU11 also the BNEG bus and ACCESS 3, BNEG terminal.

If: 48 V and event code persists. –

If: Battery voltage and charge level is correct. –

•

Then check ACCESS 3 +B and BNEG cable connections.

If: +B and BNEG cable connections are OK. –

Then verify the battery voltage and charge level.

Then check FU11.

If: Less than 48 V. –

If: Battery voltage is not correct or discharged. –

If: 0 V

Then configure the battery.

If: Battery configuration is correct. –

•

If: Battery configuration is incorrect. –

•

Step 3: Check for +BV between ACCESS 3 +BV terminal and BNEG terminal.

Then replace ACCESS 3.

Then proceed to Step 2.

Step 2: Check for +BV between CA401-1 and BNEG.

•

If: 48 V –

•

If: Voltage is above 0 V but less than 48 V. –

•

Then check wire #2902 between CA206-8 and CA401-1.

If: Voltage is above 0 V but less than 48V. –

•

Then check for +BV between CA206-8 and BNEG.

If: 48 V. –

•

Then proceed to Step 3.

Then check FU8.

If: FU8 is OK. –

Then check wire #2986 between K2 and CA204-4.

Figure 13082-01

M4.8-1960-030 03 Rev. 5/09

292

TSP 6000 Series

Crown 2006 PF15107-23 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 3 Event Code 321

Full traction is disabled.

ACCESS 3 module internal temperature less than -25 °C (-13 °F). Full traction is disabled. Step 1: Determine the ambient temperature of the environment.

•

Then ACCESS 3 heat sink must be warmed to operate.

If: Ambient temperature is above -25 °C (-13 °F) and event code persists. –

Then replace ACCESS 3.

•

–

•

Step 1: Check for proper mounting of ACCESS 3. If: ACCESS 3 not mounted tightly to truck wall. Then properly secure ACCESS 3 to truck (refer to service manual for screw torque).

If: ACCESS 3 is mounted properly. –

If: Battery voltage and charge level is correct.

•

–

•

Then check for +BV between CA206-8 and BNEG.

If: 48 V. Then check wire #2902 between CA206-8 and CA401-1.

If: Voltage is above 0V but less than 48 V. –

Heavy current draw by M1 will increase ACCESS 3 operating temperature.

Then proceed to Step 3.

If: Voltage is above 0 V but less than 48 V. –

•

Then check M1 for proper operation.

NOTE

•

Then proceed to Step 2.

If: 48 V. –

•

Full traction is disabled.

•

Then charge or change the battery.

Step 2: Check for +BV between CA401-1 and BNEG.

ACCESS 3 has internal temperature in excess of 85 °C (185 °F).

–

Then verify the battery voltage and charge level.

If: Battery is not correct or discharged –

•

Then configure the battery.

If: Battery configuration is correct.

–

Event Code 322

•

If: Battery configuration is incorrect. –

If: Ambient temperature is below -25 °C (-13 °F). –

•

Step 1: Check the feature menu for proper battery configuration.

Then check FU8.

If: FU8 is OK –

Then check wire #2986 between K2 and CA204-4.

If: M1 is OK and event code persists. –

Then replace ACCESS 3.

Event Code 323 and 324 ACCESS 3 module +BV cutback. Procedures listed apply to Event Codes 323 and 324.

NOTE If: Occurs with event code indicating ED system issue. Then refer to ED system event code 541 first.

Crown 2006 PF15107-24 Rev. 5/09

TSP 6000 Series

M4.8-1960-031 03 Rev. 5/09

293

ELECTRICAL SYSTEM Event Codes - ACCESS 3 Step 3: Check for +BV between ACCESS 3 between +B and BNEG terminals.

Event Code 325

•

ACCESS 3 module 5 V for ECR7 is out of range.

If: 0 V. –

•

If: Less than 48 V.

Step 1: Check for 5 V between wire #706 CA401-26 and BNEG.

–

•

Then check ACCESS 3 +B and BNEG cable connections.

Then cable connections between ED1 and ED2 (if present) and FU11 also the BNEG bus and ACCESS 3, BNEG terminal.

•

Then replace ACCESS 3.

Then remove wire #706 from CA401-26 and check for 5 V between CA401-26 and BNEG.

If: 5 V. –

•

Then replace ACCESS 3.

If: Less than 5V. –

•

If: 48 V and event code persists. –

If: 5 V (± 0.1 V) and event code persists. –

If: +B and BNEG cable connections are OK. –

•

Traction is disabled.

Then check FU11.

Then reconnect wire #706 and proceed to Step 2.

If: Less than 5 V. –

Then replace ACCESS 3.

Step 2: Disconnect CA409 from traction feedback splitter (FSB). Check for 5 V between CA401-26 and BNEG.

•

If: 5 V. –

•

If: Less than 5 V. –

•

Then disconnect CA408 from FSB and check for 5 V between CA401-26 and BNEG.

If: 5 V. –

•

Then replace ECR7.

Then replace FSB.

If: Less than 5 V. –

Then check the wiring between CA401-26 and FSB.

Figure 13082-01

M4.8-1960-033 03 Rev. 5/09

294

TSP 6000 Series

Crown 2006 PF15107-25 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 3 •

To test output driver connect the DVOM positive lead to CA612-1 and the negative lead to BNEG. Key truck ON while pressing the up and down arrow keys, select PDS A4.4.14 on menu. Press and hold the enter key (turns ON driver) 5 V = OFF and 0 V = ON.

Event Code 327 ACCESS 3 module pedestrian detection system (PDS) Quit Button driver pin #20 over current. Full traction is disabled.

NOTE Event code is logged under the following condition(s). • Driver is drawing too much current.

•

Figure 13083-01

Step 1: Check for shorts. PDS wire #109 to CA612-2, wire #59104 CA612-2 to CA401-20. If wiring is shorted to +B the PDS or ACCESS 3 could be damaged.

•

Event Code 326

Damaged PDS.

If: Wiring is OK. –

ACCESS 3 module pedestrian detection system (PDS) Platform Down driver pin #19 over current. Full traction is disabled.

•

If: PDS is OK. –

Event code is logged under the following condition(s). • Driver is drawing too much current. Damaged PDS.

Step 1: Check for shorts. PDS wire #901 to CA612-1, wire #59103 CA612-1 to CA401-19. If wiring is shorted to +B the PDS or ACCESS 3 could be damaged.

•

If: Wiring is OK. –

•

Then replace ACCESS 3.

NOTE

•

Then check for damage to PDS.

ACCESS analyzer menu. • To view output driver key truck ON while pressing the up arrow key, select PDS A3.4.15. • To test output driver connect the DVOM positive lead to CA612-2 and negative lead to BNEG. Key truck ON while pressing the up and down arrow key, select PDS A4.4.14 on menu. Press and hold the enter key (turns ON driver) 5 V = OFF and 0 V = ON.

Then check for damage to PDS.

If: PDS is OK. –

Then replace ACCESS 3.

NOTE ACCESS analyzer menu. • To view output driver key truck ON while pressing the up arrow key, select PDS A3.4.14. Crown 2006 PF15107-26 Rev. 5/09

TSP 6000 Series

M4.8-1960-034 03 Rev. 5/09

295

ELECTRICAL SYSTEM Event Codes - ACCESS 3 –

•

Then replace TS1.

If: TS1 is OK and the event code persists. –

Then replace ACCESS 3.

Figure 13235-01

Event Code 328

Figure 13084-01

ACCESS 3 module traction motor (M1) temperature above acceptable range.

Event Code 331

Traction is disabled.

ACCESS 3 module pedestrian detection system (PDS) End of Aisle driver pin #6 shorted, open.

Step 1: Check M1 for proper operation.

•

If: Conditions such as vibration or high pitch sound. Then repair or replace M1.

NOTE

If: M1 is OK and event code persists.

Event code is logged under the following condition(s). • Short circuit between ACCESS 3, PDS, wiring and +B. • Open circuit internal to PDS system or wiring.

–

•

Full traction is disabled.

–

Then replace ACCESS 3.

Event Code 329

•

Damaged PDS.

ACCESS 3 module traction motor (M1) temperature sensor (TS1) out of range.

Step 1: Check for shorts. PDS wire to CA611-8, wire #59101 CA611-8 to CA401-6.

Traction is disabled.

•

Step 1: Check M1 sensor wiring for opens or shorts. Wire #103 between CA401-8 and CA408-9, wire #514 between CA401-7 to CA408-6 also black lead from CA409-5 to TS1, white lead from CA409-6 and CA408-6 to CA409-6.

•

If: An open or short exists. –

•

–

Then check TS1 sensor.

Then check the wiring for an open.

If: Wiring is OK and the event code persists. –

Then replace the PDS.

If: PDS is OK. –

If: Wiring is OK. –

•

Then repair or replace the wiring.

If: No short exists.

Then replace ACCESS 3.

NOTE ACCESS analyzer menu.

If: TS1 sensor is bad.

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296

TSP 6000 Series

Crown 2006 PF15107-27 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 3 • •

To view output driver key truck ON while pressing the up arrow key, select PDS A3.4.16. To test the output driver connect the DVOM positive lead to CA611-8 and negative lead to BNEG. Key truck ON while pressing the up and down arrow keys, select PDS A4.4.16 on menu. Press and hold the enter key (turns ON driver) 5 V = OFF and 0 V = ON.

Event Code 332

–

•

Step 1: Follow the ED system trouble shooting procedure for event code 541.

•

ACCESS 3 module travel alarm (ALM2) wiring open or short. Full traction disabled.

•

If: ALM2 is ON continuously. –

•

Then a short exists between BNEG and ALM2 or wire #5912.

If: 48 V while output is active. –

Then replace ACCESS 3.

Then remove wire #2940 from CA401-13 and check the voltage at ACCESS 3, CA401-13.

Then replace ACCESS 3.

If: 48 V –

•

Then monitor for subsequent 333 events as the fault may be intermittent wiring.

If: 0 V –

•

If: 0 V and ALM2 sounds.

Then replace ACCESS 3.

•

Then replace ALM2.

If: 0 V –

•

–

Step 2: ALM2 is not ON continuously. Check the voltage between wire #2940 CA401-13 and BNEG.

•

If: 0 V and ALM2 is quiet. –

If: ALM2 OFF. –

Then proceed to Step 3.

Step 3: Enter 2-Button Mode in the ALM2 test menu. Connect the DVOM from CA401-4 to BNEG and check the voltage while the output is active.

•

If: ALM2 remains ON. –

•

Then remove wire #5912 from CA401-4.

Then fault is in the wiring between ALM2- and CA401-4.

If: ALM2+, ALM2-, and CA401-4 all at 48 V. –

Step 1: Does ALM2 sound continuously?

Then replace ALM2.

If: ALM2+ and ALM2- both at 48 V but CA401-4 near 0 V. –

•

Then fault is in the wiring between CA401-13 and ALM2+.

If: ALM2+ at 48 V but ALM2- near 0V. –

•

Event Code 333

Then check the voltage from ALM2+, ALM2-, and CA401-4 to BNEG.

If: ALM2+ not 48 V. –

ACCESS 3 module ED open or shorted driver.

Then fault is in the wiring or ALM2 between CA401-13 and CA401-4.

If: 48 V –

•

Steering, traction and hydraulics are disabled.

If: 0 V –

•

Then replace ACCESS 3.

Then connect wire #2940 and remove wire #5912 from CA401-4.

If: 48 V Figure 13085-01 Crown 2006 PF15107-28 Rev. 5/09

TSP 6000 Series

M4.8-1960-036 03 Rev. 5/09

297

ELECTRICAL SYSTEM Event Codes - ACCESS 3 Event Code 334 ACCESS 3 module pedestrian detection system (PDS) In Aisle driver pin #3 shorted, open. Full traction is disabled.

NOTE Event code is logged under the following condition(s). • Short circuit between ACCESS 3, PDS, wiring and +B. • Open circuit internal to PDS system or wiring.

•

Damaged PDS.

Step 1: Check for shorts. PDS wire to CA611-7, wire #5999 CA611-7 to CA401-3.

•

If: No short exists. –

• •

Event Code 336

Then check the wiring for an open.

Traction encoder (ECR7) count error.

If: Wiring is OK and event code persists. –

Traction is disabled.

Then replace PDS.

Step 1: Check for event codes 325, 369, 522 and 523. If these event codes have been logged resolve them before proceeding.

If: PDS is OK. –

Figure 13235-01

Then replace ACCESS 3.

The following event codes all pertain to ECR7.

NOTE ACCESS analyzer menu. • To view output driver key truck ON while pressing the up arrow key, select PDS A3.4.17. • To test output driver connect the DVOM positive lead to CA611-7 and negative lead to BNEG. Key truck ON while pressing the up and down arrow keys, select PDS A4.4.17 on menu. Press and hold the enter key (turns ON driver) 5 V = OFF and 0 V = ON.

336: ECR7 one or both channels lost by ACCESS 3 during travel. 373: ECR7 one or both channels not sensed by ACCESS 3 at traction breakout. 565: ECR7 one or both channels not sensed by ACCESS 5. Step 2: Event code 373.

•

If: Event code 373 is logged. –

Then an open ECR7 channel exists, Check the wiring between FSB (traction feedback splitter) CA408 and ACCESS 3, CA401. Wire #009 CA401-31 to CA408-7, wire #10 CA401-32 to CA408-8.

Step 3: Event code 336.

•

If: Event code 336 is logged. –

•

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Then key truck OFF then ON and command traction.

If: Event code 373 is logged.

TSP 6000 Series

Crown 2006 PF15107-29 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 3 –

•

Then check the wiring between FSB CA408 and ACCESS 3, CA401. Wire #706 CA401-26 to CA408-5, wire #514 CA401-7 to CA408-6.

•

Then repair or replace cable or connections.

If: All three cables are OK. –

Then check continuity at M1 terminals U - V, V - W and W - U.

If: Any terminals read open. –

Then replace FSB.

Then replace M1.

If: All read OK. –

If: Event code persists. –

If: Connection is open. –

•

If: Wiring is OK. –

•

If: Truck creeps slowly then shuts down without logging event code. –

•

Then an open ECR7 channel exists, Check the wiring between FSB CA408 and ACCESS 3, CA401. Wire #009 CA401-31 to CA408-7, wire #10 CA401-32 to CA408-8.

Then replace ACCESS 3.

Event Code 346

Then replace ECR7.

ACCESS 3 module default parameters not loaded. Traction is disabled. Step 1: Replace ACCESS 3 with another or download default parameters to existing module.

Event Code 347 ACCESS 3 module interlock sequence parameter setup error. Traction is disabled. Step 1: Perform reload parameter procedure.

•

If: Event code persists after parameter reload. –

Then replace ACCESS 3.

Event Code 349 Figure 13083-01

Traction is disabled.

Event Code 337

Step 1: Key truck OFF then ON.

ACCESS 3 module traction motor (M1) open. Traction is disabled.

Event Code 351 ACCESS 3 module parameter invalid value.

NOTE

Traction is disabled.

Event code is logged if M1 is open. Step 1: Check continuity of M1 phase cables from ACCESS 3 terminals to corresponding M1 terminals.

Crown 2006 PF15107-30 Rev. 5/09

ACCESS 3 module parameter change during operation.

Step 1: Replace ACCESS 3 or download default parameters to an existing module.

TSP 6000 Series

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ELECTRICAL SYSTEM Event Codes - ACCESS 3 Event Code 368

•

If: Less than 5 V. –

ACCESS 3 module VCM program error.

Then repair or replace wiring between ACCESS 3 and FSB.

Traction is disabled. Step 1: Key truck OFF then ON.

•

If: Event code clears. –

•

Then truck is operation ready.

If: Event code persists. –

Then replace ACCESS 3.

Event Code 369 ACCESS 3 module traction encoder (ECR7) 5V out of range. Traction is disabled. Step 1: Measure the voltage between wire #706 CA401-26 and BNEG.

•

If: Less than 5 V. –

•

Then proceed to Step 2.

If: 5 V and event code persists. –

Figure 13083-01

Then replace ACCESS 3.

Step 2: Remove wire #706 from CA401-26 and measure the voltage between CA401-26 and BNEG.

• •

Traction and lift are disabled.

–

Step 1: Note event codes that are displayed or flashed.

•

Then reconnect wire #706 and disconnect ECR7 from CA409. Using a DVOM check the voltage between CA401-26 and BNEG.

If: Event code 503 is displayed on ACCESS 1, event code 272 is flashed on ACCESS 3. –

If: 5 V. Then replace ECR7 and its wiring.

If: Less than 5 V. –

•

Then replace ACCESS 3.

If: 5 V.

–

•

ACCESS 3 module CAN timeout.

If: Less than 5 V.

–

•

Event Code 372

•

Then disconnect CA408 at FSB and using a DVOM check the voltage between wire #706 and BNEG.

If: Event codes 408, 409, 605, 708, and 709, are displayed on ACCESS 1 and event code 272 is flashed on ACCESS 3. –

If: 5 V. –

Then replace FSB.

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Then check the connection of CAN wires #019 between ACCESS 3, CA401-23 and power unit distribution panel, CA201-7, wire #018 between ACCESS 3, CA401-35 and power unit distribution panel CA201-1. Also refer to procedure for event code 503.

TSP 6000 Series

Then check the connection of CAN wires #003 between ACCESS 5, CA402-4 and power unit distribution panel CA201-8, wire #004 between ACCESS 5, CA402-5 and power unit distribu-

Crown 2006 PF15107-31 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 3 tion panel, CA201-2. Also refer to the procedure for event code 605.

•

If: Event code 373 is logged. –

•

If: Truck creeps slowly then shuts down without logging event code. –

•

Then check the wiring between FSB CA408 and ACCESS 3, CA401. Wire #706 CA401-26 to CA408-5, wire #514 CA401-7 to CA408-6.

If: Wiring is OK. –

•

Then an open ECR7 channel exists, Check wiring between FSB CA408 and ACCESS 3, CA401. Wire #009 CA401-31 to CA408-7, wire #10 CA401-32 to CA408-8.

Then replace FSB.

If: Event code persists. –

Then replace ECR7.

Figure 13086-01

Event Code 373 Traction encoder (ECR7) count error. Traction is disabled. Step 1: Check for event codes 325, 369, 522 and 523. If these event codes have been logged resolve them before proceeding. The following event codes all pertain to ECR7. 336: ECR7 one or both channels are lost by ACCESS 3 during travel. 373: ECR7 one or both channels not sensed by ACCESS 3 at traction breakout. 565: ECR7 one or both channels not sensed by ACCESS 5. Step 2: Event code 373.

•

If: Event code 373 is logged. –

Then an open ECR7 channel exists, Check wiring between FSB (traction feedback splitter) CA408 and ACCESS 3, CA401. Wire #009 CA401-31 to CA408-7, wire #10 CA401-32 to CA408-8.

Figure 13083-01

Event Code 378 ACCESS 3 module internal fault.

Step 3: Event code 336.

Traction is disabled.

•

Step 1: Turn key truck OFF then ON.

If: Event code 336 is logged. –

Then key truck OFF then ON and command traction.

Crown 2006 PF15107-32 Rev. 5/09

•

If: Event code persists. –

TSP 6000 Series

Then replace ACCESS 3.

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ELECTRICAL SYSTEM Event Codes - ACCESS 4

Event Codes - ACCESS 4

•

If: Greater than 60 Ω. –

Event Code 400 ACCESS 4 or ACCESS 8 module CAN error.

•

Main and auxiliary raise or lower are disabled.

ACCESS 4 CAN bus communication with ACCESS 8 has not occurred within a specified time. Step 1: Key truck ON and check the status of ACCESS 8 indicator lights are ON.

•

If: 120 Ω and event code persists. Then replace ACCESS 8.

Then problem is in the wiring between ACCESS 8, CA504-3 and CA504-4 and the platform distribution panel CA106-3 and CA603-10. Check wire condition and connections.

Then using a DVOM check for +BV between CA504-1 and CA504-2.

Then replace ACCESS 8.

If: 0 V. –

•

Then check RES3 located in the wire harness between CA703-1 and CA703-12.

If: 48 V. –

•

If: 120 Ω. –

•

Then replace ACCESS 5.

If: ACCESS 8 indicator lights are OFF. –

•

–

If: ACCESS 8 indicator lights are ON. –

If: Greater than 120 Ω. –

NOTE

Then the CAN bus terminating resistors may be open. Disconnect CA402 from ACCESS 5 and using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

Then the problem is in the wiring. Check wire #2995 CA504-1 to CA318-6, BLU wire CA318-6 to CA317-6, wire #2963 CA317-6 to CA103-15 and wire #520 CA504-2 to CA505-1. Repair or replace if necessary. Check fuse FU18 on the platform distribution panel.

If: Wiring is OK and the event code persists. –

Then check ACCESS 4 wire #029 CA314-3 to CA106-9 and wire #028, CA314-4 to CA106-1.

Figure 13546-01

CAN communication line test: Key truck OFF and using a DVOM check the resistance between CA504-3 (CAN_H) and CA504-4 (CAN_L) on ACCESS 8, resistance should be approximately 60 Ω.

•

If: Approximately 0 Ω. –

Then a short exists between CAN_H and CAN_L. Check the wiring and ACCESS modules for shorts. Repair or replace as needed.

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TSP 6000 Series

Figure 13547-01

Crown 2006 PF15107-33 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 4 Event Code 402

•

If: Greater than 60 Ω. –

ACCESS 4 or ACCESS 1 module CAN error. Main and auxiliary raise, lower are disabled.

NOTE

•

ACCESS 4 CAN bus communication with ACCESS 1 has not occurred within a specified time. If: Event code 402 is displayed on ACCESS 1. Then an intermittent connection exists. Refer to intermittent connection test below. If: Event code 402 is blinking on ACCESS 4 but is not displayed on ACCESS 1. Then proceed to Step 1.

If: 120 Ω. –

•

Then check RES3 located in the wire harness between CA703-1 and CA703-12.

If: 120 Ω and event code persists. –

•

Then the CAN bus terminating resistors may be open. Remove CA402 from ACCESS 5 and using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

Then replace ACCESS 1.

If: Greater than 120 Ω. –

Then replace ACCESS 5.

Step 1: Key truck ON and verify the status of ACCESS 1 indicator lights.

Intermittent connection test.

•

If: ACCESS 1 indicator lights are ON. –

•

If: ACCESS 1 indicator lights are OFF. –

•

Then an intermittent connection exists in ACCESS 1 wiring. Check wire #022, CA304-5 to CA106-2 and wire #027, CA304-4 to CA106-4.

If: Event codes 400, 403, 407, 408, or 409 are also displayed. –

Then an intermittent connection exists in ACCESS 4 wiring. Check wire #029, CA314-3 to CA106-9 and wire #028, CA314-4 to CA106-1.

Then replace ACCESS 1.

If: 0 V. –

•

Then using a DVOM check for +BV between CA304-1 and CA304-2.

–

If: 48 V. –

•

Then the problem is in the wiring between ACCESS 1, CA304-4and CA304-5 and the platform distribution panel CA106-2 and CA106-8. Check the wiring condition and connections.

If: Event codes 501 or 702 are also displayed.

Then check wire #2946 CA304-1 to CA103-12 and wire #512, CA304-2 to CA104-6. Repair or replace as needed.

If: Wiring is OK and event code persists. –

Then check ACCESS 4 CAN wire #029 CA314-3 to CA106-9, wire #028 CA314-4 to CA106-1. Repair or replace as needed.

Figure 13547-01

Step 2: Key truck OFF. Using a DVOM measure the resistance between CAN_H CA304-4 and CAN_L CA304-5 of ACCESS 1. The reading should be approximately 60 Ω.

•

If: Approximately 0 Ω. –

Then a short exists between CAN_H and CAN_L. Check the wiring and ACCESS modules for shorts. Repair or replace as needed. Crown 2006 PF15107-34 Rev. 5/09

TSP 6000 Series

M4.8-1960-046 03 Rev. 5/09

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ELECTRICAL SYSTEM Event Codes - ACCESS 4 –

•

Then check wire #2975, CA703-10 to CA701-3, RED wire, CA701-3 to CA105-3, wire #569, CA703-8 to CA701-1, and BLK wire, CA701-1 to CA105-1. Repair or replace as needed.

If: Event code persists. –

Then check ACCESS 4 wiring. Wire #029 CA314-3 to CA106-9 and wire #028 CA314-4 to CA106-1.

CAN communication line test: Key truck OFF and using a DVOM check the resistance between CA703-1 CAN_H and CA703-12 CAN_L, resistance should be approximately 60 Ω.

•

If: Approximately 0 Ω. –

• Figure 13548-01

If: Greater than 60 Ω. –

Event Code 403 ACCESS 4 or ACCESS 7 module CAN error. All hydraulics are disabled except limp main lower.

•

–

Step 1: Key truck ON and verify the status of ACCESS 7 indicator lights.

•

If: ACCESS 7 indicator lights are ON. –

•

Then replace ACCESS 7.

If: Greater than 120 Ω. –

Then replace ACCESS 5.

Then the problem is in the wiring between ACCESS 7, CA703-1 and CA703-12 and the platform distribution panel, CA106-6 and CA106-7. Check the wire condition and connections.

Then using a DVOM check for +BV between CA703-8 and CA703-10.

Figure 13547-01

If: 48 V. –

•

If: 120 Ω and event code persists. –

•

Then check RES3 located in the wire harness between CA703-1 and CA703-12. Replace RES3 or the wire harness.

If: ACCESS 7 indicator lights are OFF. –

•

Then the CAN bus terminating resistors may be open. Remove CA402 from ACCESS 5 and using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

If: 120 Ω.

NOTE ACCESS 4 CAN bus communication with ACCESS 7 has not occurred within a specified time.

Then a short exists between CAN_H and CAN_L. Check the wiring and ACCESS modules for shorts. Repair or replace as needed.

Then replace ACCESS 7.

If: 0 V.

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TSP 6000 Series

Crown 2006 PF15107-35 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 4 CAN communication line test: Key truck OFF and using a DVOM check the resistance between CA411-23 CAN_H and CA411-35 CAN_L, resistance should be approximately 60 Ω.

•

If: Approximately 0 Ω. –

•

If: Greater than 60 Ω. –

Figure 13549-01

•

Event Code 407 All hydraulics are disabled.

•

NOTE

Step 1: Key truck ON and verify the status of ACCESS 2 indicator lights.

•

Then replace ACCESS 5.

Then the problem is in the wiring between ACCESS 2, CA411-23 and CA411-35 and the power unit distribution panel, CA201-4 and CA201-10. Check the wire condition and connections. Figure 13547-01

Then using a DVOM check for +BV between CA411-1 and BNEG.

Then replace ACCESS 2.

If: 0 V. –

•

–

If: 48 V. –

•

If: Greater than 120 Ω.

If: ACCESS 2 indicator lights are OFF. –

•

Then replace ACCESS 2.

If: ACCESS 2 indicator lights are ON. –

•

Then check RES3 located in the wire harness between CA703-1 and CA703-12. replace RES3 or the wire harness.

If: 120 Ω and event code persists. –

ACCESS 4 CAN bus communication with ACCESS 2 has not occurred within a specified time.

Then the CAN bus terminating resistors may be open. Remove CA402 from ACCESS 5 and using a DVOM, check the resistance between CA402-4 and CA402-5 of ACCESS 5.

If: 120 Ω. –

ACCESS 4 or ACCESS 2 module CAN error.

Then a short exists between CAN_H and CAN_L. Check the wiring and ACCESS modules for shorts. Repair or replace as needed.

Then the problem is in the wire #2904 CA411-1 to CA206-10, check the wire.

If: Event code persists. –

Figure 13550-01

Then check ACCESS 4 wire #029, CA314-3 to CA106-9 and wire #028, CA314-4 to CA106-1.

Crown 2006 PF15107-36 Rev. 5/09

TSP 6000 Series

M4.8-1960-049 03 Rev. 5/09

305

ELECTRICAL SYSTEM Event Codes - ACCESS 4 CA402-5, CAN_L, resistance should be approximately 60 Ω.

•

If: Approximately 0 Ω. –

• Figure 13552-01

If: Greater than 60 Ω. –

Event Code 408 and 409 ACCESS 4 or ACCESS 5 module CAN error. Procedures listed apply to Event Codes 408 and 409.

•

NOTE ACCESS 4 CAN bus communication with ACCESS 5 has not occurred within a specified time. Step 1: Key truck ON and verify the status of ACCESS 5 indicator lights.

•

–

Then replace ACCESS 5.

Then the problem is in the wiring between ACCESS 5, CA402-4 and CA402-5 and the power unit distribution panel, CA201-8 and CA201-2. Check wire condition and connections.

Then using a DVOM check for +BV between CA403-10 and BNEG.

Figure 13547-01

Then replace ACCESS 5.

If: 0 V. –

•

If: Greater than 120 Ω.

If: 48 V. –

•

Then replace ACCESS 4.

If: ACCESS 5 indicator lights are OFF. –

•

If: 120 Ω and event code persists. –

•

Then check RES3 located in the wire harness between CA703-1 and CA703-12. Replace resistor or wire harness.

If: ACCESS 5 indicator lights are ON. –

•

Then the CAN bus terminating resistors may be open. Remove CA402 from ACCESS 5 and using a DVOM check the resistance between CA402-4 and CA402-5 of ACCESS 5.

If: 120 Ω. –

Main raise or lower are disabled.

Then a short exists between CAN_H and CAN_L. Check the wiring and ACCESS modules for shorts. Repair or replace as needed.

Then the problem is in wire #2903, CA403-10 to CA206-9. Figure 13552-01

If: Event code persists. –

Then check ACCESS 4 wire #029, CA314-3 to CA106-9 and wire #028, CA314-4 to CA106-1.

CAN communication line test: Key truck OFF and using a DVOM check the resistance of ACCESS 5 between CA402-4, CAN_H and

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TSP 6000 Series

Crown 2006 PF15107-37 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 4 –

•

Then a short exists in the seat locking solenoid (EML). Replace EML.

If: Event code 436 is logged. –

Then check wire #5913, CA 316-1 to CA312-7 and wire #2989, CA316-6 to CA312-8 for a short(s).

Figure 13553-01

Event Code 411 and 430 ACCESS 4 module internal fault.

Figure 13554-01

Procedures listed apply to event codes 411 through 430. Main raise or lower and auxiliary hydraulics are disabled. Step 1: Replace ACCESS 4.

Event Code 437 ACCESS 4 module main height encoder ECR5 power supply wire open. Traction, main raise, main lower and auxiliary raise are in limp mode.

Event Code 436 ACCESS 4 module seat locking solenoid over current. No action taken.

Step 1: Check ECR5 wiring. RED wire ECR5 to CA310-3, wire #709 CA310-3 to CA313-9 and BLK wire ECR5 to CA310-4, wire #519 to CA313-10.

•

If: Wiring is OK and event code persists. –

NOTE Event code is logged if excessive current flows through the module driver CA312-7.

•

Then replace ECR5.

If: Event code persists. –

Then replace ACCESS 4.

Step 1: Remove wire #5913 from connector, CA312-7. Key truck ON and activate the seat release switch (RSS) check event code.

•

If: Event code 436 is logged. –

•

Then replace ACCESS 4.

If: Event code 436 is not logged. –

Then a short exists in the wiring and or solenoid. Reinstall wire #5913 and proceed to Step 2.

Figure 13555-01

Step 2: Remove BLK wire from CA316-1. Key truck ON and activate the seat release switch (RSS) check event code.

•

If: Event code 436 is not logged. Crown 2006 PF15107-38 Rev. 5/09

TSP 6000 Series

M4.8-1960-051 03 Rev. 5/09

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ELECTRICAL SYSTEM Event Codes - ACCESS 4 Event Code 438

Event Code 439

ACCESS 4 module main height encoder ECR5 channel CHA or CHB open.

ACCESS 4 module main height encoder ECR5 count error.

Traction, main raise or lower and auxiliary raise in limp mode.

Step 1: Check ECR5 wiring. ORG wire ECR5 to CA310-1, wire #032 CA310-1 to CA313-11, WHT ECR5 to wire CA310-2, wire #033 CA310-2 to CA313-12 and BLK wire ECR5 to CA310-4, wire #519 CA310-4 to CA313-10.

•

If: Wiring is OK and event code persists. –

NOTE Event code will log if load is too great preventing main raise movement. Step 1: Check the operation of the main raise, lower.

•

Then proceed to Step 2.

–

Step 2: Check event codes.

•

If: Event codes 437 or 447 have been logged. –

•

Then resolve them before proceeding to step 3.

–

Then replace ECR5.

If: Event code persists. Then replace ACCESS 4.

Then reconnect ORG and WHT wires. Check the voltage between ORG wire CA310-1 and BNEG also between WHT wire CA310-2 and BNEG.

If: 5.5 V. –

•

If: Wiring is OK and event code persists.

–

Then replace ECR5.

Then check ECR5 wiring. ORG wire ECR5 to CA310-1, wire #032 CA310-1 to CA313-11, WHT wire ECR5 to CA310-2, wire #033 CA310-2 to CA313-12, RED wire ECR5 to CA310-3, wire #709 CA310-3 to CA313-9 and BLK wire ECR5 to CA310-4, wire #519 to CA313-10.

If: 0 V or 5 V. –

•

• •

If: Not 0 V or 5 V. –

•

–

Then proceed to Step 3.

Step 3: Disconnect ECR5 ORG and WHT wires from CA310-1 and CA310-2. Connect the DVOM from ORG wire (CH A) to BNEG, key truck ON and check the voltage. Reading should be either 0V or 5V depending on position of ECR5 disc. Perform the same test on the WHT wire (CH B).

Then check the operation of PVMR, PCBy, MPV and RV1 also check for contamination.

If: Main raise and lower operates.

If: Event code 438 is logged. –

•

If: Main raise lower does not operate.

Then replace ECR5. Figure 13555-01

If: 0 V or 5 V and event code persists. –

Then replace ACCESS 4.

Event Code 440 ACCESS 4 module main height encoder ECR5 reset error. Traction, main raise or lower and auxiliary raise in limp mode.

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TSP 6000 Series

Crown 2006 PF15107-39 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 4 Step 1: Check ECR5 wiring. ORG wire ECR5 to CA310-1, wire #032 CA310-1 to CA313-11, WHT wire ECR5 to CA310-2, wire #033 CA310-2 to CA313-12, RED wire ECR5 to CA310-3, wire #709 CA310-3 to CA313-9 and BLK wire ECR5 to CA310-4, wire #519 to CA313-10.

•

If: Wiring is bad. –

•

Step 1: Key truck ON while pressing the up arrow key. Select HCS (height cable switch) A2.4.13 on the display menu and view the reading. If: Switch shows closed. –

Then check the height reset switch HGTRS1 and associated wiring. BLK wire HGTRS1 to CA308, wire #5920 to CA311-5 also BLK wire HGTRS1 to CA308, wire #535 to CA101-2.

•

–

Then replace HGTRS1.

If: Event code persists. –

•

Then replace ACCESS 4.

Then check the adjustment of HCS.

If: HCS adjustment is OK and event code persists. –

•

Then check HCS wiring. ACCESS 2 wire #2916, CA411-9 to CA414-7, WHT wire CA414-7 to HCS, BLK wire HCS to CA414-8, wire #2918 CA414-8 to CA206-12.

If: Wiring is OK. –

•

Then raise and block the platform (blocking per section MA Control of Hazardous Energy of Service and Parts manual). Inspect the main mast height encoder ECR5 cable for tears, frays or other damage.

If: Cable is OK. –

•

Then status is normal. Event code may have occurred due to the above note.

If: Switch shows open.

If: Wiring is OK and event code persists. –

•

Event code could be logged if truck is operating on a rough floor surface or an abrupt raise, lower handle movements.

•

If: Wiring is OK. –

•

Then repair or replace the wiring.

NOTE

Then replace HCS.

If: Event code persists. –

Then replace ACCESS 2.

Figure 13558-01

Event Code 441 ACCESS 4 module main mast broken height sensor cable. Traction, main raise or lower and auxiliary raise in limp mode.

Figure 13559-01

Crown 2006 PF15107-40 Rev. 5/09

TSP 6000 Series

M4.8-1960-054 03 Rev. 5/09

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ELECTRICAL SYSTEM Event Codes - ACCESS 4 Event Code 442

–

Then replace ACCESS 4.

ACCESS 4 module main height encoder ECR5 count error. Traction, main raise or lower and auxiliary raise in limp mode. Step 1: Check the main mast for drifting down.

•

If: Main mast is drifting down. –

•

Then check if the main mast is moving up during auxiliary raise.

Then check the PVMR valve for proper operation.

If: No mast movement and event code persists.

ACCESS 4 module cable tension slack. Main and auxiliary raise, lower are disabled.

NOTE Event code could be logged if truck is operating on a rough floor surface or an abrupt raise or lower handle movements.

If: Event code persists.

Step 1: Check F2 in the features menu and verify the correct mast type is selected. If TF is selected and mast type is TN or TT, event code 444 will be logged.

–

•

–

•

Event Code 444

If: Main mast is moving up during auxiliary raise. –

•

Figure 13555-01

If: Main mast is not drifting down. –

•

Then check the hydraulic system. Manual lowering valve (MVL), defective or contaminated SVML or a stuck CV2.

Then replace ECR5.

Then replace ACCESS 4.

–

Event Code 443

Traction, main raise or lower and auxiliary raise in limp mode.

NOTE

•

Step 1: Check ECR5 wiring. ORG wire ECR5 to CA310-1, wire #032 to CA313-11 also WHT wire ECR5 to CA310-2, wire #033 CA310-2 to CA313-12.

•

–

If: Wiring is OK.

•

Then check the hose take-up cable adjustment (see Mast - Hose Take-Up Cable in the Service and Parts manual).

If: Cable tension adjustment is OK and the event code persists.

Then correct the wiring.

Then replace ECR5.

Then status is normal. Event code may have occurred due to the above Note.

If: CTS switch shows open. –

If: Wires are reversed.

–

•

If: CTS switch shows closed. –

Main mast must be lowered then raised passed height reset switch (HGTRS1) to reset the encoder counts.

–

Then proceed to Step 2.

Step 2: Key truck ON while pressing the up arrow key. Select cable tension switch (CTS) A2.4.9 on the display menu and view the reading.

ACCESS 4 module main height encoder ECR5 counting in reverse direction.

•

If: Mast type is correct and event code persists.

Then check CTS wiring. BLK wire CTS to CA416-1, wire #2915 CA416-1 to CA411-10 also WHT wire CTS to CA416-2, wire #2938 CA416-2 to CA206-15.

If: Wiring is bad.

If: Event code persists.

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TSP 6000 Series

Crown 2006 PF15107-41 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 4 –

•

If: Wiring is OK and the event code persists. –

•

Then repair or replace wiring.

Then replace CTS.

–

•

If: Event code persists.

If: CHS1 and CHS2 adjustment is OK.

Then replace ACCESS 2.

If: CSH1 and CHS2 resistance is OK and event code persists. –

•

Then check CHS1 and CHS2 resistance approximately 0 Ω.

Then check CHS wiring. ACCESS 4 CA311-12 wire #5917 to CA309-4, BLK wire CA309-4 to CHS1, BLK wire CHS1 to CHS2, BLK wire CHS2 to CA309-1 and wire #532 CA309-1 to CA101-4.

If: Wiring is OK and event code persists. –

Then replace CHS1 or CHS2.

Figure 13560-01

Event Code 445 ACCESS 4 module main chain slack. Traction, main and auxiliary lower, pivot, traverse, fork extend or retract are disabled.

NOTE To prevent nuisance logging check for proper chain adjustment. Step 1: Key truck ON while pressing the up arrow key. Select chain slack switches (CHS1-2) A2.2.6 on display menu and the view reading.

•

Then status is normal. Event code may have occurred due to the above Note.

ACCESS 4 module main chain break. Traction, main and auxiliary raise or lower, pivot, traverse, fork extend or retract are disabled.

If: HS1 and CHS2 switch shows open. –

•

Event Code 446

If: CHS1 and CHS2 switch shows closed. –

Figure 13561-01

Then check chain adjustment (see Platform in the Service and Parts manual).

NOTE

If: Chain adjustment is OK and event code persists.

To prevent nuisance logging check for proper chain adjustment.

–

Step 1: Check main mast chains for breakage.

Then check CHS1 and CHS2 adjustment (see Componentry in the Service and Parts manual). Crown 2006 PF15107-42 Rev. 5/09

•

If: Chains are OK.

TSP 6000 Series

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311

ELECTRICAL SYSTEM Event Codes - ACCESS 4 –

Event Code 447

Then proceed to Step 2.

Step 2: Key truck ON while pressing the up arrow key. Select chain break switches (CHS3-4) A2.2.8 on display menu and view the reading.

•

If: CHS3 and CHS4 switch shows closed. –

•

If: CHS3 and CHS4 switch shows open. –

•

Then check CSH3 and CHS4 adjustment (see section Componentry in the Service and Parts manual).

If: CHS3 and CHS4 adjustment is OK. –

•

Then status is normal. Event code may have occurred due to the above note.

Then check CHS3 and CHS4 resistance approximately 0 Ω.

ACCESS 4 module main height encoder ECR5 power supply out of range. Traction, main raise, lower and auxiliary raise in limp mode.

NOTE Event code is logged if ECR5 power supply voltage is in the 4.75 to 5.5 V range. Step 1: Connect the DVOM positive lead to CA313-9 and negative lead to BNEG. Key truck ON and check the voltage reading.

•

If: Not between 4.75 to 5.5V. –

If: CHS3 and CHS4 resistance is OK. –

Then check CHS3, 4 wiring. ACCESS 4 CA311-11 wire #5916 to CA309-3, BLK wire CA309-3 to CHS3, BLK wire CHS3 to CHS4, BLK wire CHS4 to CA309-2 and wire #533 to CA101-5.

•

If: 4.75 to 5.5 V. –

•

Then a short exists in ECR5 wiring. Check ECR5 wiring, ORG wire ECR5 to CA310-1, wire #032 CA310-1 to CA313-11, WHT wire ECR5 to CA310-2, wire #033 CA310-2 to CA313-12, RED wire ECR5 to CA310-3, wire #709 CA310-3 to CA313-9 and BLK wire ECR5 to CA310-4, wire #519 to CA313-10.

If: Wiring is OK and event code persists. –

•

Then disconnect wire #709 from CA313-9. Check the voltage between CA313-9 and BNEG.

Then replace ECR5.

If: Not between 4.75 to 5.5 V. –

Then replace ACCESS 4.

Figure 13555-01 Figure 13561-01

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312

TSP 6000 Series

Crown 2006 PF15107-43 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 4 Event Code 491 Through Event Code 499 ACCESS 4 module internal fault. Procedures listed apply to event codes 491 through 499. All hydraulic functions are disabled. Step 1: Reprogram ACCESS 4.

•

If: Event code persists. –

Then replace ACCESS 4.

Crown 2006 PF15107-44 Rev. 5/09

TSP 6000 Series

M4.8-1960-058 03 Rev. 5/09

313

ELECTRICAL SYSTEM Event Codes - ACCESS 5

Event Codes - ACCESS 5

Check wire #003 between CA201-8 and CA402-4, wire #004 between CA201-2 and CA402-5.

Event Code 501

Step 3: No communication between ACCESS 1 and ACCESS 5.

ACCESS 1 module CAN timeout.

•

Traction and hydraulics are disabled. Condition 1: Intermittent communications between ACCESS 1 and ACCESS 5 can cause ACCESS 5 to flash and log event code 501. ACCESS 1 must receive the event code 501 from ACCESS 5 to illuminate the wrench light. Display of the wrench would indicate communications between ACCESS 1 and ACCESS 5 were disrupted. Condition 2: No communications between ACCESS 1 and ACCESS 5. ACCESS 5 will flash event code 501, however event code will not be logged and the wrench light will not illuminate. Traction, hydraulics and steering are disabled.

–

•

If: ACCESS 1 wrench light illuminated and event code 501 is logged. –

Then proceed to Step 2.

•

If: ACCESS 5 flashes event code 501 and the wrench light is not illuminated.

•

Then proceed to Step 3.

Then key truck ON and using a DVOM check for +BV between CA304-1 and BNEG.

If: 0 V. –

Then check wire 2946 between CA103-12 and CA304-1 and CA104-6 and CA304-2.

•

If: ACCESS 1 turns ON and ALM1 sounds continuously.

•

Then check CAN wiring between platform distribution panel and ACCESS 1. Check wire #027 between CA106-2 and CA304-4, wire #022 between CA106-8 and CA304-5 and mast cable 2 from CA107-7 & -8 to CA413-7 & -8. Wire #005, CA4137 to CA201-9 and wire #006, CA413-8 to CA210-3.

•

If: ACCESS 1 wrench light illuminates and logs event codes 104 and 605.

Step 1: Event condition.

•

If: ACCESS 1 fails to turn ON.

–

Then check CAN wiring between power unit distribution panel and ACCESS 5. Check wire #003 between CA201-8 and CA402-4, wire #004 between CA201-2 and CA402-5.

Step 2: Intermittent communication between ACCESS 1 and ACCESS 5. Check for additional event codes.

•

If: Event codes 402 and 702 have been logged. –

•

If: Wiring is OK and event code persists. –

•

Then the fault is in the wiring between the platform distribution panel and ACCESS 1, check the wiring and connections. Wire #2946 between CA103-12 and CA304-1, wire #512 between CA104-6 and CA304-2, wire #027 between CA106-8 and CA304-4, wire #022 between CA106-2 and CA304-5.

Then clean the wire connections and connectors.

If: Event codes 408, 409, 564, 605, 708 and 709 have been logged. –

Then the fault is in the wiring between the power unit distribution panel and ACCESS 5.

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TSP 6000 Series

Figure 13110-01

Crown 2006 PF15107-45 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5

Figure 13111-01

Event Code 502

Figure 13550-01

ACCESS 5 communication (CAN) with ACCESS 2 module timeout. ED, steering, traction and hydraulics are disabled. Step 1: Check for power to ACCESS 2.

•

If: ACCESS 3 indicator lights are ON. –

•

Then repair or replace the wiring.

–

Then using a DVOM check for +BV between CA411-1 and BNEG.

•

Then check wire #2904 CA206-10 to CA411-1.

•

–

Then replace ACCESS 2.

Crown 2006 PF15107-46 Rev. 5/09

•

Then the fault is in the wiring between the power unit distribution panel and ACCESS 3, using a DVOM check for +BV between CA401-1 and BNEG.

If: 48 V. –

If: Wiring is OK and event code persists.

Then clean the wire connections and connectors.

If: ACCESS 3 indicator lights are OFF. –

Then repair or replace the wiring.

Then the fault is in the wiring between the power unit distribution panel and ACCESS 3, check the wiring and connections. Wire #2902 between CA206-8 and CA401-1. Wire #019 between CA201-7 and CA401-23. Wire #018 between CA201-1 and CA401-35.

If: Wiring is OK.

If: Wiring is bad. –

•

If: 0 V. –

•

Then check the wiring and connections between power unit distribution panel and ACCESS 2. Wire #023 CA201-10 to CA411-23, wire #024 CA201-4 to CA411-35 and wire #2904 CA206-10 to CA411-1.

If: ACCESS 2 indicator lights are OFF. –

•

Traction, steering, hydraulics and ED are disabled.

If: Wiring is bad. –

•

ACCESS 3 module CAN timeout. Step 1: Check for power to ACCESS 3.

If: ACCESS 2 indicator lights are ON. –

Event Code 503

Then replace ACCESS 3.

If: 0 V. –

Then the fault is in the wiring or connections between the power unit distribution panel and ACCESS 3. Check wire #2902 between CA206-8 and CA401-1.

TSP 6000 Series

M4.8-1960-060 03 Rev. 5/09

315

ELECTRICAL SYSTEM Event Codes - ACCESS 5

Figure 13113-01

Event Code 504 ACCESS 4 module CAN timeout. Figure 13114-01

Traction, steering, lift hydraulics and ED are disabled.

Event Code 505

Step 1: Check for power to ACCESS 4.

•

If: ACCESS 4 indicator lights are ON. –

•

If: Wiring is OK. –

•

No action taken.

NOTE Event code can occur due to electronic noise or timing error. Under this condition the truck will restore operation with no effect on performance.

Then clean all contacts.

If: Event is frequent. –

Then the fault is in the wiring between the platform distribution panel and ACCESS 4, using a DVOM check for +BV between CA314-1 and BNEG.

If: 48 V. –

ACCESS 5 module CAN error.

•

If: ACCESS 4 indicator lights are OFF. –

•

Then the fault is in the wiring between the platform distribution panel and ACCESS 4, check the wiring and connections. Wire #518 between CA314-2 and CA101-1. Wire #028 between CA314-4 and CA106-1. Wire #029 between CA314-3 and CA106-9. Wire #2950 between CA314-1 and CA103-13.

Step 1: Check CAN_H and CAN_L wiring and connections between the platform distribution panel and ACCESS 7. Wire #059 between CA703-1 and wire #047 also wire #047 to CA701-8. Then check wire #058 between CA703-12 and wire #046 also wire #046 to CA701-7.

•

Then replace ACCESS 4.

If: Wiring is OK. –

If: 0 V. –

Then the fault is in the wiring between the platform distribution panel and ACCESS 4. Check wire #2950 between CA314-1 and CA103-13, wire #518 between CA314-2 and CA101-1.

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Then proceed to step 1.

•

Then check the BRN wire between CA701-7 and CA106-6 also the YEL wire between CA701-8 and CA106-7.

If: Wiring is OK. –

TSP 6000 Series

Then clean the wire connections.

Crown 2006 PF15107-47 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 Wire #2975 between CA703-10 and CA701-3. RED wire between CA701-3 and CA105-3.

Figure 13600-01

Event Code 507 ACCESS 7 module CAN timeout. Figure 13115-01

Traction, steering, hydraulics and ED are disabled. Step 1: Check for power to ACCESS 7.

•

If: ACCESS 7 indicator lights are ON. –

•

ACCESS 8 module CAN timeout. Traction, steering, hydraulics and ED are disabled. Step 1: Check for power to ACCESS 8.

•

If: ACCESS 8 indicator lights are ON. –

Then the fault is in the wiring between the platform distribution panel and ACCESS 7, using a DVOM check for +BV between CA703-10 and BNEG.

If: 48 V. –

•

Then the fault is in the wiring between the platform distribution panel and ACCESS 7, check wiring and connections. BRN wire between CA701-7 and CA106-6. YEL wire between CA701-8 and CA106-7. BLK wire between CA701-1 and CA105-1. RED wire between CA701-3 and CA105-3. Wire #046 between CA701-7 and junction of wire #058 connected to CA703-12. Wire #047 between CA701-8 and junction of wire #059 connected to CA703-1. Wire #2975 between CA701-3 and CA703-10.

If: ACCESS 7 indicator lights are OFF. –

•

Event Code 508

Then replace ACCESS 7.

•

If: 0 V. –

If: Wiring is OK. –

Then clean wire connections and connectors.

TSP 6000 Series

M4.8-1960-063 03 Rev. 5/09

Then the fault is in the wiring between the platform distribution panel and ACCESS 7, check the wiring and connections.

Crown 2006 PF15107-48 Rev. 5/09

Then the fault is in the wiring between the platform distribution panel and ACCESS 8, check wiring and connections. Wire #036 between CA106-3 and CA317-7, YEL wire between CA317-7 and CA318-7, wire #056 between CA318-7 and CA504-4, wire #037 between CA106-10 and CA317-8, BRN wire between CA317-8 and CA318-8, wire #057 between CA318-8 and CA504-3, wire #541between CA104-7 and CA317-5, ORG wire between CA317-5 and CA318-5, wire #582 between CA318-5 and CA505-1, wire #540 between CA104-8 and CA317-4, GRN wire between CA317-4 and CA318-4, wire #583 between CA318-4 and CA505-1, wire #520 between CA505-1 and CA504-2.

317

ELECTRICAL SYSTEM Event Codes - ACCESS 5 •

–

•

Then the fault is in the wiring between the platform distribution panel and ACCESS 8, using a DVOM check for +BV between CA504-1 and BNEG.

If: Wiring is OK. –

•

–

Then replace ACCESS 8.

•

If: 0 V. –

Then the fault is in the wiring between the platform distribution panel and ACCESS 8. Check wire #2963 between CA103-15 and CA317-6, BLU wire between CA317-6 and CA318-6, wire #2995 between CA504-1 and CA318-6.

Then the fault is in the wiring between the power unit distribution panel and ACCESS 6, using a DVOM check for +BV between CA601-1 and BNEG.

If: 48 V. –

•

Then clean wire connections and connectors.

If: ACCESS 6 indicator lights are OFF.

If: 48 V. –

•

If: ACCESS 8 indicator lights are OFF.

Then replace ACCESS 6.

If: 0 V. –

Then the fault is in the wiring between the power unit distribution panel and ACCESS 6. Check wire #2905 between CA601-1 and CA206-11.

Figure 13116-01

Event Code 509 and 510 ACCESS 6 module CAN timeout. Procedures listed apply to Event Codes 509 and 510.

Figure 13117-01

No action taken.

If: ACCESS 6 indicator lights are ON.

Event Code 511 Through Event Code 521

–

ACCESS 5 module internal event.

Step 1: Check for power to ACCESS 6.

•

Then the fault is in the wiring between the power unit distribution panel and ACCESS 6. Check wiring and connections, wire #011 between CA601-4 and CA201-11, wire #012 between CA601-5 and CA201-5, wire #2905 between CA601-1 and CA206-11, wire #507 between CA601-2 and CA406 -+BV.

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Procedures listed apply to Event Codes 511 through 521.

TSP 6000 Series

Crown 2006 PF15107-49 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 tween CA403-20 and CA410-4, wire #516 between CA403-12 and CA410-2.

NOTE All event codes shown indicate internal module events that are not field serviceable. Event codes 511, 512, 515-521: Traction, steering and hydraulics are disabled.

•

If: 5 V. –

Then replace ECR6.

Event codes 513, 514: No action taken.

Step 3: ECR7, disconnect CA409 from FSB. Using a DVOM check for 5 V between CA403-21 and BNEG.

Step 1: Replace ACCESS 5.

•

If: 5 V. –

Event Code 522 and 523

•

ACCESS 5 Module 5 V power supply out of range.

If: Less than 5 V. –

Procedures listed apply to Event Codes 522 and 523. Steering and traction are disabled. Step 1: Using a DVOM, check for 5 V between CA403-20 and BNEG also CA403-21 and BNEG.

• •

Then the fault is in ECR6 or wiring. Reconnect wire #707 to CA403-20 and proceed to Step 2.

Then remove wire #702 from CA403-21.Using a DVOM check for 5 V between CA403-21 and BNEG.

If: 5 V (± 0.1 V). –

•

Then remove wire #707 from CA403-20 and using a DVOM check for 5 V between CA403-20 and BNEG.

Then the fault is in the wiring ACCESS 5 and CA408. Check wire #702 between CA403-21 and CA408-1, wire #511 between CA403-22 and CA408-2.

If: Less than 5 V. –

•

–

If: 5 V (± 0.1 V). –

•

Then replace FSB.

If: Less than 5 V.

If: Less than 5 V. –

•

Then replace ACCESS 5.

Then disconnect CA408 from FSB. Using a DVOM check for 5 V between CA403-21 and BNEG.

If: 5 V. –

•

If: 5 V (± 0.1 V) and event code persists. –

•

Then replace ECR7.

Then the fault is in ECR7 or wiring. Reconnect wire #702 to CA403 21 and proceed to Step 3.

If: Less than 5 V and event code persists. –

Then replace ACCESS 5.

Step 2: ECR6, disconnect CA410. Using a DVOM check for 5 V between CA403-20 and BNEG.

•

If: Less than 5 V. –

Then the fault is in the wiring between ACCESS 5 and CA410. Check wire #707 be-

Crown 2006 PF15107-50 Rev. 5/09

TSP 6000 Series

M4.8-1960-065 03 Rev. 5/09

319

ELECTRICAL SYSTEM Event Codes - ACCESS 5 –

•

If: Voltage is within acceptable range of 20 to 65 V and event code persists. –

•

Then monitor the voltage while operating the truck.

Then replace ACCESS 5.

If: Voltage is below acceptable range of 20 to 65 V. –

Then check the power cables, battery state of charge and condition.

Event Code 526 and 527 ACCESS 5 module +BV brake voltage out of range. Procedures listed apply to Event Codes 526 and 527. Brake +BV above range: Full traction is disabled. Brake +BV below range: Traction is disabled.

NOTE Event code 527 is logged when both inner and outer brake coils are below range. Event Code 526 is logged when either inner or outer brake coil is above range. Step 1: Check the status of event codes 528, 529, 530, 531 and 540. If any of these event codes have been logged resolve them before proceeding with event codes 526 and 527. Figure 13118-01

•

Event Code 524 and 525

If: Only event codes 526 and 527 are persistently logged. –

Then replace ACCESS 5.

ACCESS 5 module +BV out of range. Procedures listed apply to Event Codes 524 and 525. Full Traction is disabled.

Event Code 528 and 529 ACCESS 5 module inner brake +BV out of range.

NOTE

Procedures listed apply to event codes 528 and 529.

Check status of event code 540 (incorrect battery voltage detected). If logged, resolve before proceeding with event code 524 and 525. Events 540, 524 and 525 depend on ACCESS 5, +BV, 540 event codes indicates a failure of a pre-operation test.

Event code 528: Inner brake +BV above range: Full traction is disabled.

Step 1: Using a DVOM check the voltage between ACCESS 5 +BV and BNEG.

•

If: 48 V.

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Event code 529: Inner brake +BV below range: Traction is disabled. Step 1: Check the status of event code 540.

•

If: Event code 540 is logged. –

TSP 6000 Series

Then resolve event code 540 before proceeding with event codes 528 and 529.

Crown 2006 PF15107-51 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 Event Code 530 and 531

Step 2: Check FU9.

•

If: FU9 is open. –

•

ACCESS 5 module outer brake +BV out of range.

Then replace FU9.

Procedures listed apply to event codes 530 and 531.

If: FU9 is OK. –

Event code 530: Outer brake +BV above range: Full traction is disabled.

Then proceed to Step 3.

Event code 531: Outer brake +BV below range: Traction is disabled.

Step 3: Check operation of ED1.

•

If: Contacts close. –

•

Then remove wire #2911 from CA403-7. Check the voltage between wire #2911 and BNEG.

If: FU10 is open –

•

Then replace FU10.

If: FU10 is OK. –

Then replace ACCESS 5.

Then proceed to Step 3.

Step 3: Check operation of ED1.

Then fault is in ED load buss. Refer to event code 541 trouble shooting procedures.

If: Greater than 48 V. –

Then resolve before proceeding with event codes 530 and 531.

Step 2: Check FU10.

If: Less than 48 V. –

•

Then replace ACCESS 5.

If: 48 V. –

If: Event code 540 is logged. –

If: Less than 48 V. –

•

If: 48 V. –

•

Step 1: Check status of event code 540.

Then check the voltage between CA403-7 and BNEG.

Then refer to event code 540 trouble shooting procedures.

•

If: Contacts close. –

•

If: 48 V. –

•

Then replace ACCESS 5.

If: Less than 48 V. –

•

Then remove wire #2910 from CA403-9. Check the voltage between wire #2910 and BNEG.

If: 48 V. –

•

Then replace ACCESS 5.

If: Less than 48 V. –

•

Then check the voltage between CA403-9 and BNEG.

Then the fault is in the ED load buss. Refer to event code 541 trouble shooting procedures.

If: Greater than 48 V. –

Then refer to event code 540 trouble shooting procedures.

TSP 6000 Series

M4.8-1960-068 03 Rev. 5/09

Figure 13119-01

Crown 2006 PF15107-52 Rev. 5/09

321

ELECTRICAL SYSTEM Event Codes - ACCESS 5 –

•

Then check the wiring between CA403-27, CA403-24, CA403-28 and CA406-1, CA406-2 and CA406-3.

If: 5 V. –

Then replace CS1.

Figure 13119-01

Event Code 532 and 533 ACCESS 5 module 5 V battery current sensor (CS1) supply out of range.

Figure 13120-01

Procedures listed apply to Event Codes 532 and 533. No action taken. Step 1: Check the voltage between CA403-27 and BNEG.

•

If: 5 V (± 0.1 V). –

•

NOTE

Then remove wire #701 from CA403-27 connector. Check for 5 V between CA403-27 and BNEG.

Then fault is CS1 or the wiring between CS1 and ACCESS 5. Reconnect wire #701and proceed to Step 2.

Check status of event codes 532, 533, 536 and 537. If logged, resolve before proceeding with event code 534 and 535. Step 1: Check the wiring between ACCESS 5 CA403-27, CA403-24, CA403-28 and CA406-1, CA406-2, CA406-3 also the wiring between CA406 and current sensor CS1.

•

If: Wiring is bad. –

If: Less than 5 V. –

•

Then replace ACCESS 5.

Step 2: Disconnect CS1 from CA406, check the voltage between CA403-27 and BNEG.

•

Procedures listed apply to event codes 534 and 535.

Then monitor.

If: 5 V. –

ACCESS 5 module battery current out of range. Traction, steering, and hydraulics are disabled.

If: Less than 5 V. –

Event Code 534 and 535

Then repair or replace the wiring.

If: Wiring is OK and event code persists. –

Then replace CS1.

If: Less than 5 V.

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TSP 6000 Series

Crown 2006 PF15107-53 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 Event Code 536

Check event codes 532 and 533 if logged resolve before event code 537.

ACCESS 5 module battery current sensor (CS1) improperly installed.

Step 1: Step off of truck to allow ED contacts to open. Wait 2 minutes for ED bus to discharge. Check the voltage between CA403-24 to BNEG.

No action taken. Check for event code 537 if logged resolve before event code 536. Step 1: Enter 1-button mode and view CS1 sensor input (A2.4.4). Command full traction then plug while viewing CS1 values.

•

If: Current value is negative during traction acceleration. –

•

If: 2.4 to 2.6 V and event code persists. –

•

If: Outside of 2.4 to 2.6 V. –

•

Then remove wire #101 from CA403-24, check the voltage between wire #101 end and BNEG.

If: Outside of 2.4 to 2.6 V. –

•

Then replace ACCESS 5.

Then replace CS1.

If: 2.4 to 2.6 V. –

Then replace ACCESS 5.

If: CS1 is not mounted correctly or wiring is bad. –

•

Then check installation of CS1 to bus bar and the wiring between ACCESS 5, CA403-27, CA403-24, CA403-28 and CA406-1, CA406-2, CA406-3 also between CA406 and CS1.

•

Then repair or replace the wiring or correctly mount CS1.

If: CS1 is installed properly, wiring is OK and event code persists. –

Then replace CS1.

Figure 13120-01

Event Code 538 and 539 ACCESS 5 module BDI voltage out of range. Procedures listed apply to event codes 538 and 539. Figure 13120-01

Event Code 537

Crown 2006 PF15107-54 Rev. 5/09

539: Full traction and lift are disabled. Step 1: Check for correct battery.

ACCESS 5 module battery current sensor (CS1) zero reading out of range. No action taken.

538: Lift is disabled.

Step 2: Key truck OFF and check FU2.

•

If: FU2 is open. –

TSP 6000 Series

Then replace FU2.

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ELECTRICAL SYSTEM Event Codes - ACCESS 5 Step 3: Check for +BV between CA403-25 and CA403-26.

•

If: Less than 48 V. –

•

Step 2: Check condition of FU9, FU10, and FU13.

–

Then check the wiring between the battery and ACCESS 5.

•

Then proceed to Step 3.

If: Fuse(s) are open. –

If: 48 V and event persists. –

If: Fuses are OK.

Then replace fuse(s).

Step 3: Key truck ON and check the pull-in of ED contacts.

Then replace ACCESS 5.

•

If: Contactor pulls in, even momentary. –

•

Then ED system is OK. Proceed to Step 4.

If: Contactor fails to pull-in. –

Then the ED bus is open. Refer to event code 541 for troubleshooting.

Step 4: Key truck OFF. Remove the +BV cable from ACCESS 5 power terminal. Key truck ON, using a DVOM check the voltage between ACCESS 5, +BV cable end and the BNEG terminal while ED is pulled in (1/2 to 1 second).

•

If: 48 V. –

•

If: Less than 48 V. –

•

Then Key truck OFF and reconnect ACCESS 5 +BV cable. Key truck ON, using a DVOM check the voltage between ACCESS 5, +BV terminal and the BNEG terminal.

Then check ED power distribution using the procedure for event code 541.

If: 48 V and event persists. –

Then replace ACCESS 5.

Figure 13121-01

Event Code 541

Event Code 540

ACCESS 5 module ED contactor failed to energize.

ACCESS 5 +BV out of range.

Traction, steering and hydraulics are disabled.

Steering, traction, and hydraulics are disabled. Step 1: Disconnect the battery and using a DVOM check the battery voltage.

•

If: 48 V (all cells good). –

•

Then proceed to Step 2.

NOTE Before proceeding check status of event codes 540 and 546. If either event has been logged resolve that issue before event code 541.

If: 24 V, 36 V or 80 V.

Step 1: Key truck ON. When self test is complete step on the brake pedals to energize the ED contactor.

–

•

Then install 48 V battery.

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If: ED fails to energize.

TSP 6000 Series

Crown 2006 PF15107-55 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 –

•

If: 0 V. –

•

Then check the wire connections between ACCESS 5, CA403-19 and ACCESS 3, CA401-5.

If: 48 V –

•

Then check for +BV across ED contactor coil.

If: 0 V. –

•

Then replace ACCESS 3.

If: 48 V. –

•

Then check for +BV between ACCESS 3 BNEG, CA401-5 and +BV.

If: 0 V. –

•

Then replace ACCESS 5.

If: 48 V. –

•

Then check for +BV between ACCESS 5 +BV, CA403-19 and BNEG.

Then disconnect wires #2901 and #2907 from the ED coil. Check the coil resistance.

If: Infinity. –

Then replace the ED contactor.

Figure 13122-01

Event Code 542 Open fuse. Steering, traction and hydraulics are disabled. Step 1: Key truck OFF. Check fuses FU9, FU10 and FU13.

•

If: Fuses are OK. –

Crown 2006 PF15107-56 Rev. 5/09

TSP 6000 Series

Then proceed to Step 2.

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ELECTRICAL SYSTEM Event Codes - ACCESS 5 •

•

If: Fuse(s) are open. –

Then replace fuse(s).

–

Step 2: Check wire #2911 between CA206-6 and CA403-7, wire #2910 between CA206-4 and CA403-9, cable from FU13 to ACCESS 5 +B terminal.

•

If: Connections are bad. –

If: Circuit is not open. Then fault is a connection between +BV terminal of ED1 (ED2 if present) and load side ED1 (ED2 if present). Check wire connections.

Event Code 544 ACCESS 5 module ED turn ON error.

Then repair or replace connections.

Traction is disabled.

NOTE ACCESS 5 internal switch is in the OFF state and not responding to the ON command. Step 1: Follow procedure for event code 541.

Event Code 545 ACCESS 5 module ED turn OFF event. Traction is disabled. Step 1: Follow procedure for event code 541, ED System Troubleshooting.

Event Code 546 Through Event Code 550 ACCESS 2 module or ACCESS 3 module failed ED load bus pre-charge. Procedures listed apply to event codes 546 through 550. Figure 13123-01

Traction, steering, hydraulics and ED are disabled. Event Code 546: General ED pre-charge failure.

Event Code 543

Event Code 547: ACCESS 3 pre-charge, power out of range.

ACCESS 5 module ED1 (ED2 if present) tips welded.

Event Code 548: ACCESS 3 pre-charge failed.

Traction, steering and hydraulics are disabled. Step 1: Check ED1 (ED2 if present) for welded tips.

Event Code 549: ACCESS 2 pre-charge, power out of range.

•

If: ED1 or ED2 tips are welded.

Event Code 550: ACCESS 2 pre-charge failed.

–

Step 1: Using a DVOM check the resistance from the ED buss, output contact to BNEG.

•

Then repair or replace tips.

If: ED1 or ED2 tips are not welded. –

Then key truck OFF and check the resistance between ED1 (ED2 if present) load bus and +BV.

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•

If: Less than 25 Ω.

TSP 6000 Series

Crown 2006 PF15107-57 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 –

Then remove bus load fuse's one at a time until the resistance increases to normal value of approximately 1 kΩ.

Event Code 551 ACCESS 5 module parameter error. Full traction is disabled.

Chart 1

Step 1: Key truck OFF then ON.

Load Removed

Disconnection Port

Corresponding ACCESS Module

Inner Brake @ PVML

FU9

ACCESS 5

Outer Brake

FU10

ACCESS 5

FU13

ACCESS 5

FU11

ACCESS 3

FU12

ACCESS 2

Step 2: Once the ED bus resistance returns to normal, note the last fuse removed and replace all others to verify the bus resistance is still OK. Step 3: Replace the module in the corresponding ACCESS Module column in the same row as the final fuse is disconnected.

•

If: Event code clears. –

•

Then truck is operation ready.

If: Event code persists. –

Then replace ACCESS 5.

Event Code 552 and 553 ACCESS 5 module parameter error. Procedures listed apply to event codes 552 and 553. No action taken. Step 1: Load default parameters and configure as required.

Event Code 554 ACCESS 5 module EAC parameter error. Full traction is disabled. Step 1: Drive truck over EAC magnets to reset data.

•

If: Event code clears. –

•

Then truck is operation ready.

If: Event code persists. –

Then replace ACCESS 5.

Event Code 555 and 556 ACCESS 5 module steering feedback encoder (ECR6) counts out of range. Procedures listed apply to event codes 555 and 556. Traction is disabled. Step 1: Check the status of event codes 522 and 523.

•

If: Event codes 522 and 523 are logged. –

Figure 13124-01

Crown 2006 PF15107-58 Rev. 5/09

TSP 6000 Series

Then resolve them before proceeding with event codes 555 and 556.

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ELECTRICAL SYSTEM Event Codes - ACCESS 5 Step 2: Using a DVOM check for 5 V between CA410-2 BNEG and CA410-4 +BV.

•

If: Low is 4.75 V or high 5.25 V. –

•

Then follow procedures for event codes 522 and 523.

If: 5 V. –

Then proceed to Step 3.

Step 3: Check the steer wheel synchronization. Enter one button mode to display ECR6 counts; rotate steer tiller in both directions while viewing counts. ECR6 counts should change smoothly and continuously as steer wheel moves. Record ECR6 counts once steer wheel is at zero position.

•

If: ECR6 counts change erratically or not at all. –

•

Event Code 557 ACCESS 5 module steering feedback encoder (ECR6) index line error. Full traction is disabled.

NOTE

Then replace ECR6.

ECR6 count indicates the wheel has passed through zero position but index signal has not indicated the same.

If: ECR6 is OK and event code persists. –

•

Figure 13125-01

If: Wiring is OK and event code persists. –

•

Then check wire #013 between CA403-13 and CA410-1, blue wire between CA410-1 and ECR6, wire #014 between CA403-14 and CA410-3, orange wire between CA410-3 and ECR6, wire #015 between CA403-23 and CA410-5, yellow wire between CA410-5 and ECR6.

Then replace ACCESS 5.

If: ECR6 counts change smoothly but count is not at zero at zero position. –

Then exit one button mode and perform ECR6 alignment.

Step 1: Check the status of event codes 522 and 523. If either has been logged resolve them before proceeding with event code 557. Step 2: Using a DVOM check for 5 V between CA410-4 +BV and CA410-2 BNEG.

•

If: Low is 4.75 V or high 5.25 V. –

•

Then follow the procedure for event codes 522 and 523.

If: 5 V. –

Then proceed to Step 3.

Step 3: Check ECR6 index wire #015 between CA403-23 and CA410-5, yellow wire between CA410-5 and ECR6.

•

If: Wiring is OK. –

Then proceed to Step 4.

Step 4: Check steer wheel synchronization. Enter one button mode to display ECR6 counts (A2.4.1); rotate M4.8-1960-077 03 Rev. 5/09

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TSP 6000 Series

Crown 2006 PF15107-59 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 the steer tiller in both directions while viewing counts. ECR6 counts should change smoothly and continuously as the steer wheel moves.

•

If: ECR6 counts change erratically or not at all. –

•

Step 1: Check the status of event codes 522 and 523. If either has been logged resolve them before proceeding with event codes 558, 559, 560 and 561. Step 2: Using a DVOM check for 5 V between CA410-4 +BV and CA410-2 BNEG.

•

Then replace ECR6.

Then replace ACCESS 5.

Then exit one button mode and perform ECR6 alignment.

•

If: Wiring is OK. –

Then proceed to Step 4.

Step 4: Check steer wheel synchronization. Enter one button mode to display ECR6 counts (A2.4.1); rotate the steer tiller in both directions while viewing counts. ECR6 counts should change smoothly and continuously as steer wheel moves. Record ECR6 counts once steer wheel is at zero position. If: ECR6 counts change erratically or not at all. –

• •

Then replace ECR6.

If: ECR6 is OK and event code persists. –

•

If: Wiring is OK and event code persists. –

Figure 13125-01

ACCESS 5 module steering feedback encoder (ECR6) error.

Then proceed to Step 3.

Step 3: Check the wire connections between ACCESS 5 A1 & A2 terminals and M3.

•

Event Code 558 Through Event Code 561

Then follow procedure for event codes 522 and 523.

If: 5 V. –

If: ECR6 counts change smoothly but count is not at zero at the zero position. –

If: Low is 4.75 V or high 5.25 V. –

If: ECR6 is OK and event code persists. –

•

Event will occur if there is no wheel movement upon command.

If: Wiring is OK and the event code persists. –

•

Then check wire #013 between CA403-13 and CA410-1, blue wire between CA410-1 and ECR6, wire #014 between CA403-14 and CA4103, orange wire between CA410-3 and ECR6, wire #015 between CA403-23 and CA410-5, yellow wire between CA410-5 and ECR6.

NOTE

Then replace ACCESS 5.

If: ECR6 counts change smoothly but count is not at zero position. –

Then exit one button mode and perform ECR6 alignment.

TSP 6000 Series

M4.8-1960-078 03 Rev. 5/09

Procedures listed apply to event codes 558 through 561. Traction and steering are disabled.

Crown 2006 PF15107-60 Rev. 5/09

329

ELECTRICAL SYSTEM Event Codes - ACCESS 5 –

Then replace ACCESS 5.

Event Code 563 ACCESS 5 module ACCESS 6 communication error. Traction is disabled.

NOTE ACCESS 5 received a wire guidance command from the guidance switch but has not seen any communication with ACCESS 6. Step 1: Verify the truck has the guidance feature.

• Figure 13125-01

Event Code 562

–

•

ACCESS 5 module steering system short circuit. Traction and steering are disabled. Step 1: Check the status of event codes 524, 525 and 540.

•

If: Event codes 524, 525 and 540 are logged. –

Then resolve event codes 524, 525 and 540 before proceeding with event code 562.

Step 2: Key truck OFF. Remove +B and BNEG cables from ACCESS 5. Step 3: Install a jumper between +B and BNEG. Using a DVOM check the following: Terminal A1 to +B - 15 kΩ. Terminal A1 to BNEG - 15 kΩ. Terminal A2 to BNEG - 15 kΩ.

•

If: Event code 563 persists. –

Then refer to event code 509.

Event Code 564 ACCESS 5 module wire guidance enable error. Traction is disabled.

NOTE ACCESS 5 received a wire guidance command from the guidance switch but wire enable setup is not active.

ACCESS 3 and ACCESS 5 module traction sensor ECR7 error.

If: Any are 5 kΩ below the value shown. Then replace ACCESS 5.

Traction, steering and hydraulics are disabled.

If: Readings are OK. –

Then check all hardware.

Event Code 565

Terminal A1 to A2 - 30 kΩ.

–

If: Guidance feature is installed. –

•

Then access the features menu F17.1 and turn guidance OFF.

Step 1: Access the features menu F17.2 and turn ON the wire guidance feature.

Terminal A2 to +B - 15 kΩ.

•

If: Guidance feature is not installed.

Then reconnect cables and proceed to Step 4.

Step 1: Check the status of event codes 325, 369, 522 and 523.

Step 4: Check A1 and A2 cables for a short.

Event codes 336, 373 and 565 all pertain to ECR7.

•

Event code 336: One or both channels lost at ACCESS 3 while truck is traveling.

If: Cables are OK and the event persists.

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330

TSP 6000 Series

Crown 2006 PF15107-61 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 Event code 373: One or both channels lost at ACCESS 3 at traction start. Event code 565: One or both channels lost at ACCESS 5 in idle or traveling.

•

If: Any of the above event codes are logged. –

Then resolve them before proceeding with event code 565.

Step 2: Clear the event log. Key truck OFF then ON and request traction.

•

If: Event code 565 is logged. –

•

If: Wiring is OK. –

•

Then check the wiring between FSB CA408 and ACCESS 3 CA401.

If: Wiring is OK. –

•

Then replace ACCESS 5.

If: Event code 373 is logged. –

•

Then replace FSB.

If: Event code persists. –

•

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

Then replace FSB.

If: Event code persists. –

Then replace ACCESS 3.

Figure 13126-01

Event Code 566 ACCESS 5 module End Aisle Control (EAC) enable error. Full traction is disabled.

NOTE EAC feature enabled, hardware not detected. Step 1: Verify truck has the EAC feature.

•

If: Truck does not have the EAC feature. –

•

If: Truck has the EAC feature. –

• Crown 2006 PF15107-62 Rev. 5/09

Then access the features menu F19.1 and disable EAC.

Then check for event code 105.

If: Event code 105 is logged.

TSP 6000 Series

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ELECTRICAL SYSTEM Event Codes - ACCESS 5 –

•

If: Connections are OK. –

•

Then check the connections to ACCESS 6.

NOTE Follow the above instructions for testing all EAC sensors. Refer to EAC sensor test and digital connections, Figure 13127-01

Then check for event code 509.

If: Event code 509 is logged. –

Then refer to procedures for event code 509.

Event Code 567 Through Event Code 570 ACCESS 5 module End Aisle Control (EAC) sensor latched ON error. Full traction is disabled.

NOTE Figure 13127-01

EAC sensor event code ID: EC567 - A1 EC568 - B1 EC569 - A2 EC570 - B2

Event Code 571 and 572

Step 1: Check the status of event codes 625 and 626. If either have been logged resolve them before proceeding with event codes 567 through 570. Step 2: To check the EAC sensors position the truck so no sensor is over a magnet. Key truck OFF, refer to the above event code ID.

•

If: Event code 567 is logged. –

•

If: Greater than 1 V. –

•

–

•

Then reconnect CA602. Remove wire #052 (EAC 1A digital) from CA607 3, connect the DVOM positive lead to wire #052 and negative lead to BNEG. Key truck ON.

If: 5 V. Then replace EAC distribution panel.

If: 0 V. –

Then replace ACCESS 6.

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Procedures listed apply to event codes 571 and 572. Full traction is disabled. Event code 571: Inner magnet error. Event code 572: Outer magnet error. Step 1: Drive truck out of the guided aisle, then re-enter.

•

If: Event does not re-occur. –

•

Then monitor.

If: Event repeats. –

Then replace ACCESS 6.

If: 0 V key truck OFF. –

•

Then check sensor A1 by disconnecting CA602 from ACCESS 6. Connect the DVOM positive lead to CA602-3 (EACA1 test) of ACCESS 6 and negative lead to CA602-2. Key truck ON and observe the meter.

ACCESS 5 module End Aisle Control (EAC) magnet error.

Then proceed to Step 2.

Step 2: Key truck ON and enter the one button mode, view EAC sensor status (A2.4.7). Acquire wire or rail by positioning the truck in an EAC zone, display the state of corresponding sensors. Slowly drive over the EAC magnets while viewing sensor state on the display. State will be closed if not detected open if detected.

•

If: Any magnet fails detection. –

•

Then check wiring of corresponding sensor.

If: All four magnets are detected. –

TSP 6000 Series

Then proceed to Step 3.

Crown 2006 PF15107-63 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 –

Step 3: Key truck ON in normal mode. Acquire the wire or rail and stop the truck outside the EAC zones, remain idle with foot on the brake. Wait 20 seconds for diagnostics to execute.

•

If: Sensors fails. –

•

Then an event code 500 or 600 level will be logged, follow procedures for that event.

If: Time elapses and no fault occurs, then the system is OK, continue to monitor.

•

If: Resistance is significantly less than 3.5 Ω. –

Event Code 576 Through Event Code 581

•

ACCESS 5 module brake current or resistance error. Procedures listed apply to event codes 576 through 581.

–

Step 1: Allow brake assembly to cool. Then remove the brake from the traction motor and disassemble to the level that the coils can be inspected. Step 2: Inspect the coils for heat damage. If: Lamination material has broken down. –

•

Then with the coils at room temperature use a DVOM and check the resistance, typical resistance of inner coil is 3.5 Ω outer coil 1.5 Ω.

Then outer brake low resistance occurred. Key truck OFF, check the wiring and resistance of the outer coil. Wire #2908 CA206-3 to CA407-1, wire #5902 CA403-8 to CA407-4, wire #2912 CA204-5 to ED contactor, and wire #2987 CA204-6 to ED contactor. Disconnect CA407, using a DVOM check outer coil resistance between pins 1 and 4, typical resistance at room temperature is 1.5 Ω.

If: Resistance is significantly less than 1.5 Ω. –

If: Coils do not appear to be damaged. –

•

Then replace the brake coils.

Then replace ACCESS 5.

If: Event code 584 or 585 have occurred.

Traction is disabled.

•

Then replace inner brake coil.

If: Resistance is close to 3.5 Ω and event code persists. –

•

Then inner brake low resistance occurred. Key truck OFF, check the wiring and resistance of the inner coil. Wire #2909 CA206-5 to CA407-2, wire #5901 CA403-6 to CA407-3, wire #2912 CA204-5 to ED contactor, and wire #2987 CA204-6 to ED contactor. Disconnect CA407, using a DVOM check inner coil resistance between pins 2 and 3, typical resistance at room temperature is 3.5 Ω.

Then replace outer brake coil.

If: Resistance is close to 1.5 Ω and event code persists. –

Then replace ACCESS 5.

If: Either coil is significantly above value. –

Then replace coil.

Event Code 582 Through Event Code 585 ACCESS 5 module brake current out of range. Procedures listed apply to event codes 582 through 585. Traction is disabled. Step 1: Identify event codes 582, 583, 584 and 585.

•

If: Event codes 582 or 583 have occurred.

Crown 2006 PF15107-64 Rev. 5/09

TSP 6000 Series

M4.8-1960-083 03 Rev. 5/09

333

ELECTRICAL SYSTEM Event Codes - ACCESS 5 •

If: Resistance is significantly less than 3.5 Ω. –

•

If: Resistance is close to 3.5 Ω and event code persists. –

•

Then Key truck OFF, check wiring and resistance of the outer coil. Wire #2908 CA206-3 to CA407-1, wire #2910 CA206-4 to CA403-9. Disconnect CA407, using a DVOM check outer coil resistance between pins 1 & 4, typical resistance at room temperature is 1.5 Ω.

If: Resistance is significantly less than 1.5 Ω. –

•

Then replace ACCESS 5.

If: Event code 587 has occurred. –

•

Then replace the inner brake coil.

Then replace the outer brake coil.

If: Resistance is close to 1.5 Ω and event code persists. –

Then replace ACCESS 5.

Figure 13128-01

Event Code 586 and 587 ACCESS 5 module brake load error. Procedures listed apply to event codes 586 and 587. Traction is disabled. Step 1: Identify event code 586 or 587.

•

If: Event code 586 occurred. –

Then Key truck OFF, check the wiring and resistance of the inner coil. Wire #2909 CA206-5 to CA407-2, wire #2911 CA206-6 to CA403-7. Unplug CA407 using a DVOM check the inner coil resistance between pins 2 & 3, typical resistance at room temperature is 3.5 Ω.

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334

TSP 6000 Series

Crown 2006 PF15107-65 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 Step 1: Identify event code 588 or 589.

•

If: Event code 588 occurred. –

•

If: FU9 is open. –

•

Then replace fuse FU10.

If: FU10 is OK. –

•

Then check fuse FU10.

If: FU10 is open. –

•

Then check wire #2912 CA204-5 to ED contactor, wire #2987 CA204-6 to ED contactor, and wire #2911 CA206-6 to CA403-7.

If: Event code 589 has occurred. –

•

Then using a DVOM check the voltage between CA403-7 and BNEG.

If: Less than 48 V. –

•

Then replace FU9.

If: FU9 is OK. –

•

Then check fuse FU9.

Then using a DVOM check the voltage between CA403-9 and BNEG.

If: Less than 48 V. –

Then check wire #2912 CA204-5 to ED contactor, wire #2987 CA204-6 to ED contactor, and wire #2910 CA206-4 to CA403-9.

TSP 6000 Series

M4.8-1960-085 03 Rev. 5/09

Figure 13128-01

Event Code 588 and 589 ACCESS 5 module brake supply voltage error. Procedures listed apply to event codes 588 and 589. Traction is disabled.

NOTE Brake power supply voltage loss could result from a failure of the ED contact to close. Other event codes are used to verify ED contact closure. If an event code has been logged that pertains to ED closure resolve it before proceeding with event codes 588 and 589. Event code 588: Inner brake voltage error. Event code 589: Outer brake voltage error. Crown 2006 PF15107-66 Rev. 5/09

335

ELECTRICAL SYSTEM Event Codes - ACCESS 5 •

If: Results of Steps 1 and 2 do not indicate a brake voltage error or a shorted brake load. –

Then replace ACCESS 5.

Event Code 592 and 593 ACCESS 5 module brake driver error. Procedures listed apply to event codes 592 and 593. Traction is disabled. Event code 592: Inner brake driver error. Event code 593: Outer brake driver error. Step 1: Refer to the procedures for event codes 582, 583, 584 and 585. Use the event code that corresponds to the specific driver (inner or outer brake coil).

•

If: Results of Step 1 do not indicate low brake resistance. –

Then replace ACCESS 5.

Event Code 594 ACCESS 5 PVML (proportional flow valve) load error. Main raise and lower are disabled. Step 1: Key truck OFF and disconnect CA403 from ACCESS 5. Using a DVOM check the resistance between wire #2985 and wire #5903. Figure 13128-01

•

If: Resistance is 25 to 35 Ω. –

Event Code 590 and 591

•

If: Resistance is 0 Ω. –

ACCESS 5 module brake driver error. Procedures listed apply to event codes 590 and 591. Traction disabled.

•

Event code 590: Inner brake driver error. Step 1: Refer to procedure for event codes 588 and 589. Use the event code that corresponds to the specific driver (inner or outer brake coil).

•

336

Then replace PVML.

If: 25 to 35 Ω. –

Step 2: Refer to the procedures for event codes 586 and 587. Use event code that corresponds to the specific driver (inner or outer brake coil).

M4.8-1960-086 03 Rev. 5/09

Then disconnect CA414 and check the resistance between wire #2928 and wire #5909 at CA414.

If: 0 Ω. –

Event code 591: Outer brake driver error.

Then replace ACCESS 5.

TSP 6000 Series

Then check wire #5903 CA403-2 to CA414-5, wire #2985 CA403-11 to wire #29110 and CA414-6.

Crown 2006 PF15107-67 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 5 Event Code 595

•

If: Resistance is 25 to 35 Ω. –

ACCESS 5 module proportional flow valve (PVML) driver error. Main raise is disabled. Step 1: Key truck ON in 1 button mode, enter the PVML monitor menu A4.4.1. Raise the platform then lower, display will indicate% of PVML (lower valve) duty cycle.

•

If: Wiring is OK and event code persists. –

Then replace ACCESS 5.

If: Display indicates a duty cycle but the platform does not lower. –

•

Then check wire #2985 CA403-11 to wire #29110, wire #29110 to CA414-6, wire #5903 CA403-2 to CA414-5, wire #5909 CA414-5 to PVML and wire #2928 CA414-6 to PVML.

Then check wire #2928 CA414-6 to PVML, wire #5909 CA414-5 to PVML, wire #5903 CA414-5 to CA403-2, and wire #29110 CA414-6 to wire #2917 CA206-7 and wire #2985 to CA403-11.

If: Wiring is OK and event code persists. –

Then replace ACCESS 5.

Figure 13129-01

Event Code 597 ACCESS 5 module proportional flow valve (PVML) driver error. Main raise and lower are disabled.

NOTE Shorted driver could be either CA403-2 shorted to BNEG or an internal short to ACCESS 5. Figure 13129-01

Event Code 596

•

ACCESS 5 module proportional flow valve (PVML) load error. Main raise is disabled. Step 1: Key truck OFF, disconnect CA403, using a DVOM check the resistance between CA403-2 and CA403-11. Crown 2006 PF15107-68 Rev. 5/09

Step 1: Key truck ON and using a DVOM, check PVML voltage between wire #5909 CA414-5 and BNEG. If: 0 V. –

•

If: FU9 is open. –

•

Then check FU9.

Then replace FU9.

If: FU9 is OK.

TSP 6000 Series

M4.8-1960-087 03 Rev. 5/09

337

ELECTRICAL SYSTEM Event Codes - ACCESS 5 –

Then remove wire #2985 from CA403-11, key truck ON, using a DVOM check voltage at PVML, wire #5909.

•

If: 0 V.

•

Then key truck OFF and remove wire #5909 from PVML. Key truck ON and check the voltage at tab on PVML that wire #5909 was removed from.

•

If: 0 V. –

•

If: +BV. –

•

Then key truck OFF and reconnect wire #5909 to PVML and remove wire #5903 from CA403-2. Key truck ON and check the voltage at PVML wire #5909.

If: 0 V. –

•

Then check the wiring between PVML and +BV.

Then check the wiring between PVML and ACCESS 5, CA403-2 and CA414-5.

If: +BV. –

Then replace ACCESS 5.

Figure 13129-01

M4.8-1960-088 03 Rev. 5/09

338

TSP 6000 Series

Crown 2006 PF15107-69 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 6

Event Codes - ACCESS 6

Event Code 611, 612 and 621 Through Event Code 628

Event Code 605

ACCESS 6 module internal module fault. Procedures listed apply to event codes 611, 612 and 621 through 628.

ACCESS 6 module CAN timeout. No action taken.

Event code 611: All functions are disabled.

Step 1: Verify the source of the event code.

•

If: ACCESS 6 flashes an event code but it is not displayed by ACCESS 1. –

•

Event code 621 through 628: Traction is disabled. Step 1: Replace ACCESS 6.

Event Code 631

If: ACCESS 1 displays event code 605.

ACCESS 6 module wire guidance sensor amplifier self-test error.

–

Traction is disabled.

Then check ACCESS 5 power ON indcator lights.

If: ACCESS 5 power ON indicator lights are ON. –

•

Then a fault is in the CAN wiring between ACCESS 6 and the power unit distribution panel. Check connectors CA201, CA601 and wire #011 CA201-11 to CA601-4 and wire #012 CA201-5 to CA601-5.

Event code 612: Traction is disabled.

Then the fault is in the CAN wiring between ACCESS 5 and the power unit distribution panel. Check connectors CA201, CA402 and wire #003 CA201-8 to CA402-4 and wire #004 CA201-2 to CA402-5.

If: ACCESS 5 power ON indicator lights are OFF. –

Then the fault is in the wiring between the power unit distribution panel and ACCESS 5. Check wire #2903 CA206-9 to CA403-10.

Step 1: This is an internal ACCESS 6 fault, replace ACCESS 6.

Event Code 632 ACCESS 6 module load wheel wire guidance sensor bar fault. Traction disabled.

NOTE Event code 632 will also be logged if the wire guidance feature is turned ON and sensor bars are not present. Verify sensor bars are installed before proceeding. Step 1: Check sensor bar 5 V supply. Connect the DVOM positive lead to CA602-22 and negative lead to BNEG. Key truck ON.

•

If: 5V sensor bar supply is OK. –

•

If: 0 V. –

•

Crown 2006 PF15107-70 Rev. 5/09

•

Then remove wire #717 from CA602-15, check the voltage between CA602-22 and BNEG.

If: 5 V the fault is in GS1 or the wiring from ACCESS 6 to GS1. –

Figure 13644-01

Then proceed to Step 2.

Then repair or replace wiring or GS1.

If: 0 V.

TSP 6000 Series

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ELECTRICAL SYSTEM Event Codes - ACCESS 6 –

•

If: 0 V. –

•

Then remove wire #718 from CA602-22, check the voltage between CA602-22 and BNEG at ACCESS 6.

NOTE

Then repair or replace wiring or GS2.

Step 2: Enter the one button mode and view the GS2 sensor values (A2.4.6) while driving slowly over the wire. The values should increase and decrease while traversing the wire.

•

If: Any one of the four coil signals fail to indicate the presence of the wire. –

•

Then check the wiring corresponding to that coil for a short or an open fault per the diagram.

Event code 633 will also be logged if the wire guidance feature is turned ON and sensor bars are not present. Verify sensor bars are installed before proceeding. Step 1: Check sensor bar 5 V supply. Connect the DVOM positive lead to CA602-15 and negative lead to BNEG. Key truck ON.

• •

Replace GS2.

•

Replace ACCESS 6.

Then remove wire #718 from CA602-22, check the voltage between CA602-22 and BNEG at ACCESS 6.

If: 0 V. –

•

Then repair or replace wiring or GS1.

If: 0 V. –

•

Then remove wire #717 from CA602-15, check the voltage between CA602-22 and BNEG.

If: 5 V the fault is in GS1 or the wiring from ACCESS 6 to GS1. –

•

Then proceed to Step 2.

If: 0 V. –

If: Fault persists. –

If: 5V sensor bar supply is OK. –

If: Wiring is OK. –

•

ACCESS 6 module steer wheel wire guidance sensor bar fault. Traction is disabled.

Then replace ACCESS 6.

If: 5 V the fault is in GS2 or the wiring from ACCESS 6 to GS2. –

Event Code 633

Then replace ACCESS 6.

If: 5 V the fault is in GS2 or the wiring from ACCESS 6 to GS2. –

Then repair or replace wiring or GS2.

Step 2: Enter one button mode and view the GS1 sensor values (A2.4.5) while driving slowly over the wire. The values should increase and decrease while traversing the wire.

•

If: Any one of the four coil signals fail to indicate the presence of the wire. –

Figure 13645-01

•

If: Wiring is OK. –

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Then check the wiring corresponding to that coil for a short or an open fault per the diagram.

TSP 6000 Series

Then replace GS1.

Crown 2006 PF15107-71 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 6 •

–

If: Fault persists. –

•

Then replace ACCESS 6.

If: Event code was not due alignment or calibration. –

•

Then calibrate truck.

Then with a Crown field strength meter check wire guide signal strength (6.25 kHz, 168 ma to 190 ma, 5.2 kHz, 100 ma to 118 ma).

If: Field strength is OK and event code persists. –

Then check floor.

NOTE Floor surface irregularities, corrupted signal due to rebar, metal pipes, underground electrical wiring in metal or plastic conduit. Any of these can affect wire guidance performance. This could be localized (i.e. section in one aisle) or wide spread.

Event Code 637 ACCESS 6 module wire guidance system loss of wire signal at both sensor bars. Brakes applied and traction is disabled. Step 1: Check for event codes 632 or 633. Figure 13645-01

•

Event Code 636

–

ACCESS 6 module allowable truck angle in relationship to guide wire has been exceeded.

• •

NOTE Event code 636 could log if the truck is driven beyond the end of the wire in auto guide. If: Event code logged by driving beyond the end of the wire in auto guide. –

•

If: Event code 632 and 633 were also logged. –

•

Then follow procedures for these event codes before continuing.

If: Event code was logged while in the aisle. –

•

Then wire guidance is OK.

Crown 2006 PF15107-72 Rev. 5/09

Then check the line driver power.

If: Line driver power is OK. –

Then check guide wire condition.

Event Code 638 and 639 ACCESS 6 module wire guidance system loss of wire signal from one of the two sensor bars. Procedures listed apply to event codes 638 & 639. Brakes applied and traction is disabled. Step 1: Check for event codes 632 or 633.

•

If: Event code 632 or 633 has been logged. –

Then check alignment of ECR6.

If: ECR6 requires realignment.

Then follow procedures for these event codes before continuing.

If: Event codes 632 or 633 have not been logged. –

Brakes applied and traction is disabled.

•

If: Event code 632 or 633 has been logged.

•

Then follow procedures for these event codes before continuing.

If: Event code 638, load wheel sensor bar, persists.

TSP 6000 Series

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ELECTRICAL SYSTEM Event Codes - ACCESS 6 –

•

If: Event code 639, steer wheel sensor bar, persists. –

•

Then check wire #116 CA603-1 to CA602-20, wire #115 CA603-2 to CA602-19, wire #114 CA603-7 to CA602-18 and wire #113 CA603-8 to CA602-17. Repair or replace as needed.

If: Event code 638 or 639 persists. –

•

Then check wire #120 CA604-1 to CA602-27, wire #119 CA604-2 to CA602-26, wire #118 CA604-7 to CA602-25 and wire #117 CA604-8 to CA602-24. Repair or replace as needed.

Then replace corresponding sensor bar.

If: Event code 638 or 639 persists after replacing sensor bar. –

Then replace ACCESS 6.

Event code 652 or 653: Sensor A1 over or under range. Event code 654 or 655: Sensor B1 over or under range. Event code 656 or 657: Sensor A2 over or under range. Event code 658 or 659: Sensor B2 over or under range. Step 1: Enter one button mode to view the EAC signal levels (A2.4.7). The single displayed value represents the signal strength in a percentage of full scale for the activated sensor. The display shall hold the peak sensed value until the next magnet detection cycle occurs. Step 2: Acquire the wire and slowly drive over the magnet in the position of the failed sensor while viewing the sensor signal strength. Signal strengths tend towards the lower range value, rather than the upper.

•

If: Signal is close to 100% and event persists. –

•

If: Wiring is OK. –

•

Then check the sensor wiring per the diagram and inspect the magnet location and floor conditions around the magnet.

If: All is OK. –

•

Then replace the EAC sensor that corresponds with the event code.

If: Signal is close to 40%, then signal strength is close to the lower range threshold. –

•

Then check the sensor wiring per the diagram.

Then replace the EAC sensor that corresponds with the event code.

If: Event Code persists. –

Then replace ACCESS 6.

Figure 13645-01

Event Code 652 Through Event Code 659 ACCESS 6 module EAC sensor signal out of range. Procedures listed apply to event codes 652 through 659. Full traction is disabled.

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TSP 6000 Series

Crown 2006 PF15107-73 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 6 –

•

If: All is OK and event code persists. –

•

• Event Code 660 Through Event Code 663

Then check that the magnet is present and the sensor wiring is correct per the diagram.

If: Magnet is present and wiring is OK. –

Figure 13646-01

Then replace the EAC sensor that corresponds with the event code.

If: The digital state shows open the entire time the sensor passes over the magnet. –

•

Check the sensor wiring per diagram and inspect the magnet location and floor conditions around the magnet.

Then replace EAC sensor that corresponds with the event code.

If: Event code persists. –

Replace ACCESS 6.

Event Code 664 Through Event Code 667

ACCESS 6 module EAC sensor digital signal error. Procedures listed apply to event codes 660 through 663.

ACCESS 6 module EAC magnet field strength weak. Procedures listed apply to event codes 664 through 667.

Full traction is disabled. Event code 660: Sensor A1 digital signal error.

Full traction is disabled.

Event code 661: Sensor B1 digital signal error.

Step 1: Check magnet location(s) for improper installation or damage (i.e. wrong pole, positional alignment, floor crack through magnet, etc.).

Event code 662: Sensor A2 digital signal error. Event code 663: Sensor B2 digital signal error. Step 1: Enter one button mode to view the EAC digital signal state (A2.4.7) corresponding to the faulted sensor. The digital state shall indicate opened if the magnet is not sensed and closed if it is sensed.

Event Code 668 Through Event Code 671

Step 2: Acquire the wire and slowly drive over the magnet in the position of the failed sensor while viewing the sensor digital state.

ACCESS 6 module EAC sensor self test error.

•

If: The digital state switches from opened to closed back to opened as the sensor passes over the magnet, the digital sense mechanism is working properly.

Full traction is disabled.

–

Event code 670: Sensor A2.

•

Then enter one button mode to view the EAC signal level corresponding to the event code.

If: Signal is close to 40%, then strength is close to the lower range threshold. Crown 2006 PF15107-74 Rev. 5/09

Procedures listed apply to event codes 668 through 671. Event code 668: Sensor A1. Event code 669: Sensor B1. Event code 671: Sensor B2. Step 1: Check sensor(s) wiring and connections as it applies to event code(s).

TSP 6000 Series

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ELECTRICAL SYSTEM Event Codes - ACCESS 6 •

If: Wiring or connections are bad. –

•

If: Wiring is OK and event code persists. –

•

Then repair or replace wiring.

Then replace EAC sensor that corresponds with event code.

If: Event code persists. –

Then replace ACCESS 6.

Event Code 672 ACCESS 6 module multiple EAC sensors active. Full traction is disabled. Step 1: Check EAC sensors for damage.

•

–

•

Then check the voltage at the corresponding test signal at CA602.

If: CA602 pin 0 V. –

•

Then replace ACCESS 6.

If: Greater than 3.5 V. –

•

Then remove the corresponding digital signal wire from CA602. Check the voltage at ACCESS 6, CA602 where the digital signal wire was removed.

If: Less than 1 V. –

•

Then move the truck away from the EAC zone where all sensors should be inactive. Check the digital signal voltages from CA602-5, CA602-8, CA602-11 and CA602-14 to BNEG.

If: Any digital signal is less than 1 V. –

•

Then replace sensor(s).

If: Sensor(s) are OK. –

•

Figure 13646-01

If: Sensor(s) is damaged.

Then replace the corresponding EAC sensor.

If: CA602 pin greater than 5 V. –

Then replace ACCESS 6.

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TSP 6000 Series

Crown 2006 PF15107-75 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7

Event Codes - ACCESS 7

–

Event Code 700

•

ACCESS 7 and ACCESS 8 module CAN timeout. Traverse, pivot, fork extend or retract are disabled. Step 1: Key truck ON and verify the status of ACCESS 8 indicator lights.

•

Then using a DVOM check for +BV between CA504-1 and CA504-2 on ACCESS 8.

If: 0 Ω. –

•

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other is internal to ACCESS 5. Check the resistance between ACCESS 7 CA703-1 and CA703-12.

Then leave the meter leads connected to CA703 and disconnect CA402 from ACCESS 5.

If: 0 Ω. –

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

Then replace ACCESS 8.

If: 0 V. –

•

If: 48 V. –

•

–

If: ACCESS 8 indicator lights are OFF. –

•

Then check the wiring between ACCESS 8 CA504-3, CA504-4 and platform distribution panel CA106-3 and CA106-10. Verify that the CAN_H and CAN_L wires are not reversed. Repair or replace as needed.

Then replace ACCESS 7.

If: Infinity Ω and event code persists.

If: ACCESS 8 indicator lights are ON. –

•

If: 0 Ω. –

•

Then disconnect CA703 from ACCESS 7 and check the resistance between module pin CA703-1 and CA703-12.

Then check the wiring connected to CA504-1 and CA504-2 and repair or replace the wiring.

If: Wiring is OK and the event code persists. –

Then check the wiring between ACCESS 7, CA703-1, CA703-12 and the platform distribution panel, CA106-6 and CA106-7. Repair or replace as needed.

Step 2: Should event code persist, key truck OFF. Check the resistance between CAN_H, CA504-3 and CAN_L, CA540-4. Resistance should be 60 Ω.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA504 from ACCESS 8 and check the resistance between module pins CA504-3 and CA504-4.

Then replace ACCESS 8.

If: Infinity Ω. Reconnect CA504 to ACCESS 8

Figure 13597-01

Crown 2006 PF15107-76 Rev. 5/09

TSP 6000 Series

M4.8-1960-096 03 Rev. 5/09

345

ELECTRICAL SYSTEM Event Codes - ACCESS 7 •

–

If: 120 Ω. –

Then the resistor in ACCESS 5 is shorted, replace ACCESS 5.

•

Event Code 701

If: 0 Ω. –

ACCESS 7 and ACCESS 4 module CAN timeout.

•

Step 1: Key truck ON and verify the status of ACCESS 4 indicator lights.

•

–

•

–

•

–

Then using a DVOM check for +BV between CA314-1 and CA314-2.

•

Then leave the meter leads connected to CA703 and disconnect CA402 from ACCESS 5.

If: 0 Ω. Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 120 Ω. –

If: 48 V.

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other is internal to ACCESS 5. Check the resistance between ACCESS 7 CA703-1 and CA703-12.

If: 0 Ω.

–

If: ACCESS 4 indicator lights are OFF.

Then replace ACCESS 4.

Then the resistor in ACCESS 5 is shorted, replace ACCESS 5.

If: 0 V. –

•

Then check the wiring between ACCESS 4, CA314-3, CA314-4 and the platform distribution panel, CA106-1 and CA106-9. Verify that CAN_H and CAN_L wires are not reversed, repair or replace as needed

–

•

If: ACCESS 4 indicator lights are ON.

Then replace ACCESS 7.

If: Infinity Ω. –

Auxiliary raise, lower, traverse, pivot, fork extend and retract are disabled.

Then disconnect CA703 from ACCESS 7 and check the resistance between module pins CA703-1 and CA703-12.

Then check wire #2950 CA314-1 to CA103-13 and wire #518 CA314-2 to CA101-1. Repair or replace as needed.

If: Wiring is OK and event code persists. –

Then check the wiring between ACCESS 7, CA703-1 and CA703-12 and the platform distribution panel, CA106-6 and CA106-7. Repair or replace as needed.

Step 2: Should event code persist, key truck OFF. Check the resistance between CAN_H, CA314-3 and CAN_L, CA314-4, resistance should be 60 Ω.

•

If: 0 Ω. –

Then a short exists between CAN_H and CAN_L. Disconnect CA314 from ACCESS 4 and check the resistance between module pins CA314-3 and CA314-4.

–

If: 0 Ω.

–

Then replace ACCESS 4.

–

If: Infinity Ω, reconnect CA314 to ACCESS 4.

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TSP 6000 Series

Crown 2006 PF15107-77 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

•

If: ACCESS 1 power on indicator lights are OFF. –

•

Then replace ACCESS 1.

If: 0 V. –

•

Then using a DVOM check for +BV between CA304-1 and CA304-2 on ACCESS 1.

If: 48 V. –

•

Then check the wiring between ACCESS 1, CA304-3 and CA304-5 and CA106-2 and CA106-8 of the platform distribution panel. Verify that CAN_H and CAN_L wires are not reversed, repair or replace as needed.

Then check the wiring connected to CA304-1 and CA304-2 to CA103-12 and FU8 on the platform distribution panel.

If: Wiring is OK and event code persists. –

Then check the wiring between ACCESS 7, CA703-1 and CA703-12 and the platform distribution panel, CA106-6 and CA106-7. Repair or replace as needed.

Step 2: Event code persists, key truck OFF and check the resistance (ACCESS 1) between CA304-4 CAN_H and CA304-4 CAN_L, should be approximately 60 Ω. Figure 13598-01

•

Event Code 702

If: 0 Ω. –

ACCESS 7 and ACCESS 1 module CAN timeout. Auxiliary raise, lower, traverse, pivot, fork extend and retract are disabled.

•

If: Event code is displayed on ACCESS 1. Then event was caused by an intermittent open wire condition. Check the wiring connections between ACCESS 1 and ACCESS 7. If: Event code 702 is blinking on ACCESS 7 indicator lights but not displayed on ACCESS 1. –

Then replace ACCESS 7.

If: Infinity Ω. –

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other is internal to ACCESS 5. Check the resistance between ACCESS 7, CA703-1 and CA703-12

TSP 6000 Series

M4.8-1960-100 03 Rev. 5/09

If: ACCESS 1 power on indicator lights are ON.

Crown 2006 PF15107-78 Rev. 5/09

Then disconnect CA703 from ACCESS 7 and check the resistance between module pins CA703-1 and CA703-12.

If: 0 Ω. –

•

Then proceed to Step 1.

Step 1: Key truck ON and verify status of ACCESS 1 power on indicator lights.

•

Then replace ACCESS 1.

If: Infinity Ω, reconnect CA304 to ACCESS 1. –

–

•

If: 0 Ω. –

NOTE

•

Then a short exists between CAN_H and CAN_L. Disconnect CA304 from ACCESS 1 and check the resistance between module pins CA304-3 and CA304-4.

347

ELECTRICAL SYSTEM Event Codes - ACCESS 7 •

–

•

Then leave the meter leads connected to CA703 and disconnect CA402 from ACCESS 5.

•

If: 0 Ω. –

•

–

If: 0 Ω.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 120 Ω. –

Then roister in ACCESS 5 is shorted, replace ACCESS 5.

If: ACCESS 2 indicator lights are OFF. –

•

Then replace ACCESS 2.

If: 0 V. –

•

Then using a DVOM check for +BV between CA411-1 and BNEG.

If: 48 V. –

•

Then check wire #023 CA411-23 to CA201-10 and wire #024 CA411-35 to CA201-4. Verify that CAN_H and CAN_L wires are not reversed, repair or replace as needed.

Then check wire #2904 CA411-1 to CA205-10 and FU8 on the platform distribution panel. Repair or replace as needed.

If: Wiring is OK and event code persists. –

Then check the wiring between ACCESS 7, CA703-1 and CA703-12 and the platform distribution panel, CA106-6 and CA106-7. Repair or replace as needed.

Step 2: Event code persists, key truck OFF, using a DVOM check the resistance (ACCESS 2) between CA411-23 CAN_H and CA411-35 CAN_L, should be 60 Ω.

•

If: 0 Ω. –

Then a short exists between CAN_H and CAN_L. Disconnect CA411 from ACCESS 2 and check the resistance between module pins CA411-23 and CA411-35.

–

If: 0 Ω.

–

Then replace ACCESS 2.

If: Infinity Ω, reconnect CA411 to ACCESS 2. –

Figure 13599-01

•

Event Code 707

If: 0 Ω. –

ACCESS 7 and ACCESS 2 module CAN timeout. Traverse, pivot, fork extend and retract are disabled.

•

–

If: ACCESS 2 indicator lights are ON.

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Then replace ACCESS 7.

If: Infinity Ω.

Step 1: Key truck ON and verify the status of ACCESS 2 indicator lights.

•

Then disconnect CA703 from ACCESS 7 and check the resistance between module pins CA703-1 and CA703-12.

TSP 6000 Series

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other one is internal to ACCESS 5. Check the resistance between ACCESS 7 CA703 -1 and CA703-12.

Crown 2006 PF15107-79 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 •

–

•

Then leave the meter leads connected to CA703 and disconnect CA402 From ACCESS 5.

If: 0 Ω. –

•

If: 0 Ω.

Then the wire harness resistor is shorted. Replace the resistor in the wire harness or replace the wire harness.

–

•

Then the resistor in ACCESS 5 is shorted, replace ACCESS 5.

If: 0 Ω. –

• •

•

Then replace ACCESS 7.

If: Infinity Ω. –

Then there are two 60 Ω resistors that connect CAN_H and CAN_L. One is located in the wire harness close to CA703 and the other one is internal to ACCESS 5. Check the resistance between ACCESS 7 CA703 -1 and CA703-12.

TSP 6000 Series

M4.8-1960-104 03 Rev. 5/09

Procedures listed apply to event codes 708 and 709. Traverse, pivot, fork extend and retract are disabled. Step 1: Key truck ON and verify the status of ACCESS 5 indicator lights. Crown 2006 PF15107-80 Rev. 5/09

Then disconnect CA703 from ACCESS 7 and check the resistance between module pins CA703-1 and CA703-12.

If: 0 Ω. –

ACCESS 7 and ACCESS 5 module CAN timeout.

Then replace ACCESS 5.

If: Infinity Ω. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA402 from ACCESS 5 and check the resistance between module pins CA402-4 and CA402-5.

If: 0 Ω. –

Event Code 708 and 709

Then check the wiring between ACCESS 7, CA703-1 and CA703-12 and the platform distribution panel, CA106-6 and CA106-7. Repair or replace as needed.

Step 2: Event code persists, key truck OFF and check the resistance (ACCESS 5) between CA402-4 CAN_H and CA402-5 CAN_L, resistance should be 60 Ω.

•

Figure 13600-01

Then check wire #2903 CA403-10 to CA206-9 and FU8 on the power unit distribution panel.

If: Wiring and FU8 are OK and event code persists. –

Figure 13550-01

Then replace ACCESS 5.

If: 0 V. –

•

Then using a DVOM check for +BV between CA403-10 and BNEG.

If: 48 V. –

•

Then check wire #003 CA402-4 to CA201-8 and wire #004 CA402-5 to CA201-2. Verify that CAN_H and CAN_L wires are not reversed. Repair or replace as needed.

If: ACCESS 5 indicator lights are OFF. –

•

If: 120 Ω.

If: ACCESS 5 indicator lights are ON.

349

ELECTRICAL SYSTEM Event Codes - ACCESS 7 •

–

•

Then leave the meter leads connected to CA703 and disconnect CA402 from ACCESS 5.

ACCESS 7 module internal error detected during self test.

If: 0 Ω. –

•

Event Code 711 Through Event Code 720

If: 0 Ω.

Then the wire harness resistor is shorted. Replace the resistor in the wire harness or replace the wire harness.

If: 120 Ω. –

Procedures listed apply to event codes 711 through 720. Auxiliary raise or lower, traverse, pivot, extend and retract are disabled. Step 1: Replace ACCESS 7.

Then the resistor in ACCESS 5 is shorted. Replace ACCESS 5.

Event Code 736 ACCESS 7 module proportional flow valve auxiliary raise (PVAR) over current. Auxiliary raise is disabled.

NOTE Event code is logged if excessive current flows through the module driver CA702-1.

Figure 13553-01

Step 1: Auxiliary fork carriage must not be at maximum height. Remove wire #5958 from connector CA702-1. Key truck ON and attempt an auxiliary raise, check event code.

•

If: Event code 736 is still the last event code logged. –

•

Then replace ACCESS 7.

If: Event code 736 is not the last event code logged. –

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5958 and proceed to Step 2.

Step 2: Auxiliary fork carriage must not be at maximum height. Remove wire #2976 from PVAR. Key truck ON and attempt an auxiliary raise, check the event code. Figure 13600-01

•

If: Event code 736 is still the last event code logged. –

•

If: Event code 736 is not the last event code logged. –

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Then a short exists in the wiring, check for shorts between wire #5958 and RED/WHT wire (#2976).

TSP 6000 Series

Then a short exists in PVAR. Replace PVAR. Crown 2006 PF15107-81 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Event Code 737 ACCESS 7 module proportional flow valve auxiliary lower (PVAL) over current. Auxiliary lower is disabled.

NOTE Event code is logged if excessive current flows through the module driver CA702-2. Step 1: Remove wire #5959 from connector CA702-2. Key truck ON and attempt an auxiliary lower, check the event code.

•

If: Event code 737 is still the last event code logged. –

•

Then replace ACCESS 7.

If: Event code 737 is not the last event code logged. –

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5959 and proceed to Step 2.

Step 2: Remove wires #2979 and #2978 from PVAL. Key truck ON and attempt an auxiliary lower, check the event code.

•

If: Event code 737 is still the last event code logged. –

•

Then a short exists in the wiring, check for shorts between wire #5959 and RED/WHT wires (#2979 and #2978).

If: Event code 737 is not the last event code logged. –

Then a short exists in PVAL. Replace PVAL. Figure 13601-01

Event Code 738 ACCESS 7 module proportional flow valve traverse motor (PVT1) over current. Traverse right is disabled.

NOTE Event code is logged if excessive current flows through the module driver CA702-4.

Crown 2006 PF15107-82 Rev. 5/09

TSP 6000 Series

M4.8-1960-106 03 Rev. 5/09

351

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Step 1: Remove wire #5961 from connector CA702-4. Key truck ON and attempt a traverse right, check event code.

Step 2: Remove wires #2984 and #2983 from PVT2. Key truck ON and attempt a traverse left, check the event code.

•

If: Event code 738 is still the last event code logged. –

•

Then replace ACCESS 7.

–

If: Event code 738 is not the last event code logged. –

•

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5961 and proceed to Step 2.

Step 2: Remove wires #2977 and #2984 from PVT1. Key truck ON and attempt a traverse right, check the event code.

•

If: Event code 738 is still the last event code logged. –

•

Then check for shorts between wire #5960 and RED/WHT wires (#2984 and #2983).

If: Event code 739 is not the last event code logged. –

Then a short exists in PVT2. Replace PVT2.

Event Code 740 ACCESS 7 module proportional flow valve pivot (PVP1) over current. Pivot clockwise is disabled.

Then check for shorts between wire #5961 and RED/WHT wires (#2977 and #2984).

NOTE Event code is logged if excessive current flows through the module driver CA702-8.

If: Event code 738 is not the last event code logged. –

If: Event code 739 is still the last event code logged.

Then a short exists in PVT1. Replace PVT1.

Event Code 739

Step 1: Remove wire #5964 from connector CA702-8. Key truck ON and attempt a pivot clockwise, check event code.

•

ACCESS 7 module proportional flow valve traverse motor (PVT2) over current.

–

•

Traverse left is disabled.

If: Event code 740 is still the last event code logged.

NOTE

Then replace ACCESS 7.

If: Event code 740 is not the last event code logged.

Event code is logged if excessive current flows through the module driver CA702-3.

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5964 and proceed to Step 2.

Step 1: Remove wire #5960 from connector CA702-3. Key truck ON and attempt traverse left, check event code.

Step 2: Remove wires #2980 and #2981 from PVP1. Key truck ON and attempt a pivot clockwise, check event code.

•

If: Event code 739 is still the last event code logged. –

•

–

Then replace ACCESS 7.

–

If: Event code 739 is not the last event code logged. –

352

•

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5960 and proceed to Step 2.

M4.8-1960-108 03 Rev. 5/09

If: Event code 740 is still the last event code logged. Then check for shorts between wire #5964 and RED/WHT wires (#2980 and #2981).

If: Event code 740 is not the last event code logged. –

TSP 6000 Series

Then a short exists in PVP1. Replace PVP1.

Crown 2006 PF15107-83 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Step 1: Remove wire #5963 from connector CA702-7. Key truck ON and attempt pivot counter clockwise, check event code.

•

If: Event code 741 is still the last event code logged. –

•

Then replace ACCESS 7.

If: Event code 741 is not the last event code logged. –

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5963 and proceed to Step 2.

Step 2: Remove wires #29106 and #2980 from PVP2. Key truck ON and attempt pivot counter clockwise, check event code.

•

If: Event code 741 is still the last event code logged. –

•

Then check for shorts between wire #5963 and RED/WHT wires #29106 and #2980.

If: Event code 741 is not the last event code logged. –

Then a short exists in PVP2. Replace PVP2.

Event Code 742 ACCESS 7 module proportional flow fork extend (PVF1) over current. Fork extend is disabled.

NOTE Event code is logged if excessive current flows through the module driver CA702-9. Figure 13601-01

Event Code 741 ACCESS 7 module proportional flow valve pivot (PVP2) over current. Pivot counter clockwise is disabled.

•

If: Event code 742 is still the last event code logged. –

•

NOTE

Then replace ACCESS 7.

If: Event code 742 is not the last event code logged. –

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5966 and proceed to Step 2.

TSP 6000 Series

M4.8-1960-109 03 Rev. 5/09

Event code is logged if excessive current flows through the module driver CA702-7.

Crown 2006 PF15107-84 Rev. 5/09

Step 1: Remove wire #5966 from connector CA702-9. Key truck ON and attempt a fork extend, check event code.

353

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Step 2: Remove wires #2983 and #2982 from PVF1. Key truck ON and attempt a fork extend, check event code.

•

If: Event code 742 is still the last event code logged. –

•

Then check for shorts between wire #5966 and RED/WHT wires #2983 and #2982.

If: Event code 742 is not the last event code logged. –

Then a short exists in PVF1. Replace PVF1.

Event Code 743 ACCESS 7 module proportional flow fork retract (PVF2) over current. Fork retract is disabled.

NOTE Event code is logged if excessive current flows through the module driver CA702-10. Step 1: Remove wire #5965 from connector CA702-10. Key truck ON and attempt a fork retract, check event code.

•

If: Event code 743 is still the last event code logged. –

•

Then replace ACCESS 7.

If: Event code 743 is not the last event code logged. –

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5965 and proceed to Step 2.

Step 2: Remove wires #2981 and #2982 from PVF2. Key truck ON and attempt a fork retract, check event code.

•

If: Event code 743 is still the last event code logged. –

•

Then check for shorts between wire #5965 and RED/WHT wires #2981 and #2982.

Then a short exists in PVF2. Replace PVF2.

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Event Code 744 ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) over current. Auxiliary lower is disabled.

NOTE

If: Event code 743 is not the last event code logged. –

Figure 13601-01

Event code is logged if excessive current flows through the module driver CA702-5.

TSP 6000 Series

Crown 2006 PF15107-85 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

Step 1: Remove wire #5962 from connector CA702-5. Key truck ON and attempt an auxiliary lower, check event code.

•

If: Event code 744 is still the last event code logged. –

•

Then replace ACCESS 7.

If: Event code 744 is not the last event code logged. –

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5962 and proceed to Step 2.

Step 2: Remove RED wire from SVAL. Key truck ON and attempt an auxiliary lower, check event code.

•

If: Event code 744 is still the last event code logged. –

•

Then check for shorts between wires #5962 and RED/WHT #2978. Short may also be present between RED and GREEN wire on SVAL.

If: Event code 744 is not the last event code logged. –

Step 2: Auxiliary fork carriage must not be at maximum height. Remove wires #2979 and #29106 from PVLH. Key truck ON and attempt auxiliary raise, check event code.

•

–

•

Auxiliary raise, traverse, pivot, fork extend and retract are disabled.

If: Event code 745 is not the last event code logged. –

Then a short exists in PVLH. Replace PVLH.

Event Code 746 ACCESS 7 module proportional flow auxiliary raise (PVAR) over current. Auxiliary raise, traverse, pivot and fork extend are disabled.

NOTE

Step 1: Connect the DVOM leads across PVAR coil terminals, leave the wires connected. Key truck ON and check the meter reading.

•

NOTE

If: Greater than 1 V. –

Event code is logged if excessive current flows through the module driver CA702-6. Step 1: Auxiliary fork carriage must not be at maximum height. Remove wire #5989 from connector CA702-6. Key truck ON and attempt an auxiliary raise, check event code.

•

Then check for shorts between wires #5989 and RED/WHT #2979 and #29106.

Event code is logged if current is flowing through the module driver supply CA702-11 when the driver is supposed to be off.

ACCESS 7 module proportional flow auxiliary relief (PVLH) over current.

If: Event code 745 is still the last event code logged. –

If: Event code 745 is still the last event code logged.

Then a short exists in SVAL. Replace SVAL.

Event Code 745

•

Then a short circuit exists in the wiring or solenoid. Reinstall wire #5989 and proceed to Step 2.

•

If: 0 V. –

•

Then a short exists. Disconnect wire #5958 from CA702-1 and Key truck ON.

Then a short exists inside the module. Replace ACCESS 7.

If: Greater than 1 V. –

Then check for shorts between wires #5958 and #2976.

Then replace ACCESS 7.

If: Event code 745 is not the last event code logged.

Crown 2006 PF15107-86 Rev. 5/09

TSP 6000 Series

M4.8-1960-112 03 Rev. 5/09

355

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Step 1: Replace ACCESS 7.

Event Code 750 ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) driver shorted or load open. Main raise, lower, auxiliary raise limp mode and auxiliary lower are disabled if SVAL is open.

NOTE Event code 750 will be logged under the following conditions: • Open in SVAL or wires connected to SVAL preventing current flow when SVAL driver is requested. • Short between BNEG and CA702-5, this places voltage across SVAL when key is turned ON. A short could be either internal or external to the module. Step 1: Disconnect the RED and GREEN SVAL wires from CA708-3 and CA708-4. Using a DVOM check the resistance of SVAL.

•

If: Less than 20 to 40 Ω. –

•

If: Infinity. –

•

Figure 13601-01

Event Code 747 Through Event Code 749 ACCESS 7 module internal driver short detected during self test. Procedures listed apply to Event Codes 747 through 749.

M4.8-1960-113 03 Rev. 5/09

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Then reconnect the wires and connect the DVOM leads across SVAL coil terminal. Key truck ON and check the meter reading.

If: Greater than 1 V. –

Then a short exists, refer to short test below.

Step 2: Connect the DVOM negative lead to BNEG and positive lead to SVAL terminal with GRN wire. Select analyzer mode ACCESS SVAL A4.1.10 on display menu, press and hold enter key (drives component), check the meter reading.

•

If: 0 V. –

Event code 747: Auxiliary lower is disabled. Event codes 748 and 749: Auxiliary raise, traverse, pivot, fork extend and retract are disabled.

Then replace SVAL.

If: Between 20 to 40 Ω and event code persists. –

•

Then replace SVAL.

•

Then positive is missing, check the RED wire SVAL to CA708-3 and wire #2978 CA708-3 to PVAL wire #2979.

If: +BV.

TSP 6000 Series

Crown 2006 PF15107-87 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

•

Then negative is missing check, GRN wire SVAL to CA708-4 and wire #5962 CA708-4 to CA702-5.

If: 24 V for 3 seconds then dropping to 0 V. –

Then circuit is OK. Check for intermittent or oxidized connections.

Short circuit test: Connect the DVOM leads across SVAL coil terminals leaving wires connected. Key truck ON and check the meter reading.

•

If: Greater than 1 V. –

•

If: 0 V. –

•

Then a short exists. Disconnect wire #5962 from CA702-5 and key truck ON.

Then short is internal to ACCESS 7, replace ACCESS 7.

If: Greater than 1 V. –

Then check for shorts between wires, GRN wire SVAL to CA708-4 and wire #5962 CA708-4 to CA702-5.

Figure 13601-01

Event Code 751 ACCESS 7 module proportional flow auxiliary relief (PVLH) driver shorted or load open. Main raise, lower limp mode and auxiliary raise are disabled. If PVLH is open, all auxiliary functions are disabled.

Crown 2006 PF15107-88 Rev. 5/09

TSP 6000 Series

M4.8-1960-115 03 Rev. 5/09

357

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

NOTE Event code 751 will be logged under the following conditions: • Open in PVLH or wires to PVLH preventing current flow when PVLH driver is requested. • A short between BNEG and CA702-6, places voltage across PVLH when key is turned ON. Fault could be internal or external to the module.

•

Then the short is internal to the module, replace ACCESS 7.

If: +BV. –

Then a short exists in the wiring, check wire #5989.

Event Code 752

Step 1: Disconnect the wires from PVLH. Using a DVOM check the coil resistance.

ACCESS 7 module proportional flow valve auxiliary raise (PVAR) driver or load open.

•

Auxiliary raise is disabled.

If: 20 to 40 Ω. –

•

NOTE

If: 0 Ω. –

•

Then coil is OK, proceed to Step 2.

Event code is logged if an open circuit exists between PVAR and the driver CA702-1.

Then replace PVLH.

If: Infinity. –

Then replace PVLH.

Step 2: Reconnect the wires to PVLH and connect the negative meter lead to BNEG and positive lead to PVLH terminal with wires #2979 and #29106. Key truck ON and check the meter reading.

•

Then proceed to Step 3.

Step 3: Connect the DVOM across PVLH coil (do not remove wires). Select analyzer mode ACCESS PVLH A4.1.3 on display menu and press and hold the enter key (drives component), check the meter reading.

•

Then a short exists in wire #5989 from CA702-6 and key truck ON.

If: 0 V.

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If: 0 V. –

•

Then a positive is missing, refer to the positive test below.

If: +BV. –

Then circuit is OK. Problem may be intermittent due to loose or oxidized connection.

If: Approximately +BV. –

•

If: 24 V for 3 seconds and drops to 0 V. –

Then a positive or negative is missing, proceed to Step 2.

Step 2: Connect the DVOM negative lead to BNEG and positive to PVAR wire #5958 (wires connected to coil). Select analyzer mode ACCESS PVAR A4.1.2 on display menu and press and hold the enter key (drives component), check meter reading.

•

Then the negative is missing. Check wire #5989.

Then PVAR is open, replace PVAR.

If: 0 V. –

If: +BV. –

Then an open exists. Check the connections of wires #2979 and #29106.

If: +BV. –

• •

If: Less than +BV. –

Step 1: Connect the DVOM leads across PVAR coil terminals. Select analyzer mode ACCESS PVAR A4.1.2 on the display menu and press and hold the enter key (drives component), check meter reading.

Then a negative is missing, refer to the negative test below.

If: 24 V for 3 seconds and drops to 0 V. –

Then circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Missing positive test: Check wire #2976 PVAR to CA702-11, wire #2974 CA703-7 to CA701-2, WHT wire CA701-2 to CA105-2.

TSP 6000 Series

Crown 2006 PF15107-89 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Missing negative test: Connect the DVOM leads between PVAR terminal with wire #5958 and CA702-1. Select analyzer mode to access PVAR A4.1.2 on display menu and press and hold the enter key (drives component), check meter reading.

•

If: +BV. –

•

Then the wiring is open between ACCESS 7 and PVAR, repair or replace the wiring.

If: 0 V. –

Then an open is internal to the module, replace ACCESS 7.

Figure 13601-01

Event Code 753 ACCESS 7 module proportional flow valve auxiliary lower (PVAL) driver or load open. Auxiliary lower is disabled.

NOTE Event code is logged if an open circuit exists between the PVAL and driver CA702-2.

Crown 2006 PF15107-90 Rev. 5/09

TSP 6000 Series

M4.8-1960-118 03 Rev. 5/09

359

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Step 1: Connect the DVOM meter leads across PVAL coil (wires connected). Select analyzer mode to access PVAL A4.1.1 on display menu and press and hold the enter key (drives component), check meter reading.

•

If: +BV. –

•

Then PVAL is open, replace PVAL.

NOTE

Then a positive or negative is missing proceed to Step 2.

Step 2: Connect the DVOM negative lead to BNEG and the positive lead to PVAL wire #5959. Select analyzer mode to access PVAL A4.1.1 on the display menu and press and hold the enter key (drives component), check meter reading.

•

If: 0 V. –

•

Then a positive is missing, refer to positive test below.

Event code is logged if an open exists preventing current flow through the driver CA702-3. Step 1: Connect the DVOM leads across PVT2 coil terminals (wires connected). Select analyzer mode to access PVT2 A4.1.5 on the display menu and press and hold the enter key (drives component), check meter reading.

• •

Then a negative is missing, refer to negative test below.

Then circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Missing positive test: Check PVAL to wires #2979 to #29106 to #2980 to #2981 to #2982 to #2983 to #2984 to #2977 to CA702-12, wire #2974 CA703-7 to CA701-2, WHT wire CA701-2 to CA105-2.

•

–

•

If: 0 V. –

•

Then the wiring is open between ACCESS 7 and PVAL, repair or replace the wiring.

•

Then a positive is missing, refer to the positive test below.

If: +BV. –

If: +BV.

Then a positive or negative is missing, proceed to Step 2.

Step 2: Connect the DVOM negative lead to BNEG and the positive lead to PVT2 wire #5960. Select analyzer mode to access PVT2 A4.1.5 on the display menu and press and hold the enter key (drives component), check meter reading.

Missing negative test: Connect the DVOM leads between the PVAL terminal with wire #5959 and CA702-2. Select analyzer mode to access PVAL A4.1.1 on the display menu and press and hold the enter key (drives component), check meter reading.

Then PVT2 is open, replace PVT2.

If: 0 V. –

If: 24 V for 3 seconds and drops to 0 V. –

If: +BV. –

•

ACCESS 7 module proportional flow valve traverse motor (PVT2) driver or load open. Traverse left is disabled.

If: 0 V. –

Event Code 754

Then a negative is missing, refer to the negative test below.

If: 24 V for 3 seconds and drops to 0 V. –

Then circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Missing positive test: Check PVT2 to wires #2984 to #2977 to CA702-12, wire #2974 CA703-7 to CA701-2, WHT wire CA701-2 to CA105-2.

If: 0 V.

Missing negative test:

–

Connect the DVOM leads between PVT2 terminal with wire #5960 and CA702-3. Select analyzer mode to access PVT2 A4.1.5 on the display menu and press and

Then an open is internal to the ACCESS 7, replace ACCESS 7.

M4.8-1960-119 03 Rev. 5/09

360

TSP 6000 Series

Crown 2006 PF15107-91 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 hold the enter key (drives component), check meter reading.

Event Code 755

•

Access 7 module proportional flow valve traverse motor (PVT1) driver or load open.

If: +BV. –

•

Then the wiring is open between ACCESS 7 and PVT2, repair or replace the wiring.

Traverse right is disabled.

NOTE

If: 0 V. –

Then an open is internal to the module, replace ACCESS 7.

Event code is logged if an open exists preventing current flow through the driver CA702-4. Step 1: Connect the DVOM leads across PVT1 coil terminals (wires connected). Select analyzer mode to access PVT1 (A4.1.4) on the display menu and press and hold the enter key (drives component), check meter reading.

•

If: +BV. –

•

Then PVT1 is open, replace PVT1.

If: 0 V. –

Then a positive or negative is missing, proceed to Step 2.

Step 2: Connect the DVOM negative lead to BNEG and positive lead to PVT1 wire #5961. Select analyzer mode to access PVT1 (A4.1.4) on display menu and press and hold enter key (drives component), check meter reading.

•

If: 0 V. –

•

If: +BV. –

•

Then a positive is missing, refer to positive test below.

Then a negative is missing, refer to negative test below.

If: 24 V for 3 seconds and drops to 0 V. –

Then circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Missing positive test: Check PVT1 to wire #2977 to CA702-12, wire #2974 CA703-7 to CA701-2, WHT wire CA701-2 to CA105-2. Missing negative test:

Figure 13601-01

Crown 2006 PF15107-92 Rev. 5/09

Connect the DVOM leads between PVT1 terminal with wire #5961 and CA702-4. Select analyzer mode to access PVT1 (A4.1.4) on the display menu and press and hold the enter key (drives component), check meter reading.

TSP 6000 Series

M4.8-1960-120 03 Rev. 5/09

361

ELECTRICAL SYSTEM Event Codes - ACCESS 7 •

If: +BV. –

•

Then the wiring is open between ACCESS 7 and PVT1, repair or replace the wiring.

If: 0 V. –

Then an open is internal to the ACCESS 7, replace ACCESS 7.

Event Code 756

Check PVP1 to wires #2981 to #2982 to #2983 to #2984 to #2977 to CA702-12, wire #2974 CA703-7 to CA701-2, WHT wire CA701-2 to CA105-2. Missing negative test: Connect the DVOM leads between PVP1 terminal with wire #5964 and CA702-8. Select analyzer mode to access PVP1 A4.1.8 on display menu and press and hold the enter key (drives component), check meter reading.

•

ACCESS 7 module proportional flow valve pivot (PVP1) driver or load open. Pivot clockwise is disabled.

–

•

NOTE

If: +BV. Then the wiring is open between ACCESS 7 and PVP1, repair or replace the wiring.

If: 0 V. –

Event code is logged if an open exists preventing current flow through the driver CA702-8.

Then an open is internal to the ACCESS 7, replace ACCESS 7.

Step 1: Connect the DVOM leads across PVP1 coil terminals (wires connected). Select analyzer mode to access PVP1 A4.1.8 on the display menu and press and hold the enter key (drives component), check meter reading.

•

If: +BV. –

•

Then PVP1 is open, replace PVP1.

If: 0 V. –

Then a positive or negative is missing, proceed to Step 2.

Step 2: Connect the DVOM negative lead to BNEG and the positive lead to PVP1 wire #5964. Select analyzer mode to access PVP1 A4.1.8 on display menu and press and hold the enter key (drives component), check meter reading.

•

If: 0 V. –

•

If: +BV. –

•

Then a positive is missing, refer to the positive test below.

Then a negative is missing, refer to the negative test below.

If: 24 V for 3 seconds and drops to 0 V. –

Then circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Missing positive test:

M4.8-1960-121 03 Rev. 5/09

362

TSP 6000 Series

Crown 2006 PF15107-93 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Event Code 758 ACCESS 7 module proportional flow auxiliary relief (PVLH) driver open. Auxiliary raise, pivot, extend, retract and traverse are disabled.

NOTE Event code is logged if an open exists preventing current flow through the driver CA702-6. Step 1: Replace ACCESS 7.

Event Code 759 ACCESS 7 module proportional flow valve pivot (PVP2) driver or load open. Pivot counter-clockwise is disabled.

NOTE Event code is logged if an open exists preventing current flow through the driver CA702-7. Step 1: Connect the DVOM leads across PVP2 coil terminals (wires connected). Select analyzer mode to access PVP2 A4.1.9 on display menu and press and hold the enter key (drives component), check meter reading.

•

If: +BV. –

•

If: 0 V. –

Figure 13601-01

Event Code 757 ACCESS 7 module auxiliary cylinder lowering solenoid valve (SVAL) open driver.

•

If: 0 V. –

Event code is logged if an open exists preventing current flow through the driver CA702-5.

•

Then a positive is missing, refer to the positive test below.

If: +BV. –

Then a negative is missing, refer to the negative test below.

TSP 6000 Series

M4.8-1960-122 03 Rev. 5/09

Step 1: Replace ACCESS 7.

Crown 2006 PF15107-94 Rev. 5/09

Then a positive or negative is missing, proceed to Step 2.

Step 2: Connect the DVOM negative lead to BNEG and the positive lead to PVP2 wire #5963. Select analyzer mode to access PVP2 A4.1.9 on display menu and press and hold the enter key (drives component), check meter reading.

Auxiliary lower is disabled.

NOTE

Then PVP2 is open, replace PVP2.

363

ELECTRICAL SYSTEM Event Codes - ACCESS 7 •

If: 24 V for 3 seconds and drops to 0 V. –

Then circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Missing positive test: Check PVP2 to wires #2980 to #2981 to #2982 to #2983 to #2984 to #2977 to CA702-12, wire #2974 CA703-7 to CA701-2, WHT wire CA701-2 to CA105-2. Missing negative test: Connect the DVOM leads between PVP2 terminal with wire #5963 and CA702-7. Select analyzer mode ACCESS PVP2 A4.1.9 on display menu and press and hold the enter key (drives component), check meter reading.

•

If: +BV. –

•

Then the wiring is open between ACCESS 7 and PVP2, repair or replace the wiring.

If: 0 V. –

Then an open is internal to the module, replace ACCESS 7.

Figure 13601-01

Event Code 760 ACCESS 7 module proportional flow fork extend (PVF1) driver or load open. Fork extend is disabled.

NOTE Event code is logged if an open exists preventing current flow through the driver CA702-9.

M4.8-1960-123 03 Rev. 5/09

364

TSP 6000 Series

Crown 2006 PF15107-95 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Step 1: Connect the DVOM leads across PVF1 coil terminals (wires connected). Select analyzer mode to access PVF1 A4.1.6 on display menu and press and hold the enter key (drives component), check meter reading.

•

If: +BV. –

•

Then a positive or negative is missing, proceed to step 2.

Step 1: Connect the DVOM leads across PVF2 coil terminals (wires connected). Select analyzer mode to access PVF2 A4.1.7 on display menu and press and hold the enter key (drives component), check meter reading.

•

–

Then a positive is missing, refer to the positive test below.

Then a negative is missing, refer to the negative test below.

If: 24 V for 3 seconds and drops to 0 V. –

•

Then circuit is OK. Problem may be intermittent due to loose or oxidized connection.

•

If: +BV. –

•

If: 0 V.

Then the wiring is open between ACCESS 7 and PVF1, repair or replace the wiring.

•

Then a positive is missing, refer to the positive test below.

If: +BV. –

Missing negative test: Connect the DVOM leads between PVF1 terminal with wire #5966 and CA702-9. Select analyzer mode ACCESS PVF1 A4.1.6 on display menu and press and hold the enter key (drives component), check meter reading.

Then a positive or negative is missing, proceed to Step 2.

Step 2: Connect the DVOM negative lead to BNEG and the positive lead to PVF2 wire #5965. Select analyzer mode to access PVF2 A4.1.7 on display menu and press and hold the enter key (drives component), check meter reading.

–

Check PVF1 to wires #2983 to #2984 to #2977 to CA702-12, wire #2974 CA703-7 to CA701-2, WHT wire CA701-2 to CA105-2.

Then PVF2 is open, replace PVF2.

If: 0 V. –

Missing positive test:

•

If: +BV.

If: +BV. –

•

Event code is logged if an open exists preventing current flow through the driver CA702-10.

If: 0 V. –

•

Fork retract is disabled.

NOTE

Step 2: Connect the DVOM negative lead to BNEG and the positive lead to PVF1 wire #5966. Select analyzer mode to access PVF1 A4.1.6 on display menu and press and hold the enter key (drives component), check meter reading.

•

ACCESS 7 module proportional flow fork retract (PVF2) driver or load open.

Then PVF1 is open, replace PVF1.

If: 0 V. –

Event Code 761

Then a negative is missing, refer to the negative test below.

If: 24 V for 3 seconds and drops to 0 V. –

Then the circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Missing positive test: Check PVF2 to wires #2982 to #2983 to #2984 to #2977 to CA702-12, wire #2974 CA703-7 to CA701-2, WHT wire CA701-2 to CA105-2.

If: 0 V.

Missing negative test:

–

Connect the DVOM leads between PVF2 terminal with wire #5965 and CA702-10. Key truck ON while pressing up and down arrow keys, select PVF2 A4.1.7 on

Then an open is internal to the ACCESS 7, replace ACCESS 7.

Crown 2006 PF15107-96 Rev. 5/09

TSP 6000 Series

M4.8-1960-124 03 Rev. 5/09

365

ELECTRICAL SYSTEM Event Codes - ACCESS 7 display menu. Press and hold the enter key (drives component), check meter reading.

Event Code 762

•

ACCESS 7 module load sense transducer (LS) open.

If: +BV. –

•

Then the wiring is open between ACCESS 7 and PVF2, repair or replace the wiring.

Traction in limp mode.

NOTE

If: 0 V. –

Then an open is internal to the ACCESS 7, replace ACCESS 7.

Event code is logged if an open exists preventing current flow through the load sense pressure transducer CA704-2. Step 1: Connect the DVOM negative lead to BNEG and the positive lead to CA704-2 (wires connected). Key truck ON and check meter reading.

•

If: 12 to 15 V. –

•

If: 0 V. –

•

Then an open exists in the wiring or LS is defective. Check the BLK wire LS to CA711, BLK wire CA711 to CA708-1, wire #121 CA708-1 to CA704-2. RED Wire LS to CA711, WHT wire CA711 to CA708-2, wire #401 CA708-2 to CA704-3.

If: Wiring is OK. –

•

Then an open exists internal to ACCESS 7, replace ACCESS 7.

Then replace LS.

If: 0.8 to 5 V and event code persists. –

Then the circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Event Code 763 ACCESS 7 module load sense transducer (LS) shorted. Traction in limp mode.

NOTE Event code is logged if a short exists, allowing excessive current to flow through LS CA704-2.

Figure 13601-01

Step 1: Disconnect wire #121 from CA704-2. Connect the DVOM positive lead to wire #121 and negative lead to BNEG, key truck ON and check meter reading.

• M4.8-1960-125 03 Rev. 5/09

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If: 12 to 15 V.

TSP 6000 Series

Crown 2006 PF15107-97 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

•

Then replace wire #121 and proceed to Step 2.

If: +BV. –

Then a short exists. Check BLK wire LS to CA711, BLK wire CA711 to CA708-1, wire #121 CA708-1 to CA704-2. RED Wire LS to CA711, WHT wire CA711 to CA708-2, wire #401 CA708-2 to CA704-3.

Step 2: Reconnect wire #121. Connect the DVOM positive lead to wire #121 CA704-2 and negative lead to BNEG, key truck ON and check meter reading.

•

• •

Then an open or short to frame exists between POT5 and CA704-8. Check wiring to POT5 and CA704-7, CA704-8 and CA704-9.

If: Wiring is OK. –

Then LS is defective, replace LS.

Then replace POT5.

If: 5 V or greater. –

If: 0.8 to 5 V and event code persists. –

If: Wiring is OK. –

If: 12 to 15 V. –

•

and CA704-7, CA704-9 is shorted to truck frame or BNEG. Check the wiring.

Then replace POT5.

If: 0.5 to 4.5 V –

Then circuit is OK.

Then the circuit is OK. Problem may be intermittent due to loose or oxidized connection.

Figure 13606-01

Event Code 765 ACCESS 7 module pivot potentiometer (POT5) voltage fluctuation. Figure 13605-01

Traction in limp mode.

Event Code 764

NOTE

ACCESS 7 module pivot position potentiometer (POT5) above or below electrical limit.

Event code is logged if a the voltage change should occur at CA704-7 with no pivot command.

Traction in limp mode.

Step 1: Check pivot pot cable.

•

NOTE Event code is logged if the voltage at CA704-7 is above or below electrical limit. Step 1: Key truck ON while pressing the up arrow key, select POT5 A2.1.3 on display menu. View the reading on display.

•

If: Approximately 0 V. –

Then an open exists between CA704-7 or CA704-9 and POT5 or a wire between POT5 Crown 2006 PF15107-98 Rev. 5/09

If: Cable is off pulley. –

•

Then reinstall cable and check for cause.

If: Cable is on the pulley. –

Then proceed to Step 2.

Step 2: Verify if pivot occurs when other hydraulic functions are performed.

•

If: Forks are not pivoting and event code is logged. –

TSP 6000 Series

Then replace POT5.

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ELECTRICAL SYSTEM Event Codes - ACCESS 7 •

–

•

If: Wiring is not cut or shorted to frame and the event code still exists. –

•

Then check wire #5963 CA702-7 to PVP2 for short to frame.

Then check POT5 wiring between CA706-A, -B, -C and CA704-7, VCA704-8 and CA704-9.

If: Wiring is OK and event code persists. –

Then replace ACCESS 7.

If: Wiring is OK. –

•

Then proceed to Step 2.

Step 2: Check wiring and connections between PVP1, PVP2 and ACCESS 7.

Then check for contamination in PVP or C +BV4.

If: Counter clockwise pivot occurs and event code is logged. –

If: Cable is on the pulley. –

Then check wire #5964, CA702-8 to PVP1 for short to frame.

If: Wiring is OK. –

•

If: Clockwise pivot occurs and event code is logged.

Then check for contamination in PVP or C +BV3.

If: No contamination is present and event code persists. –

Then replace ACCESS 7. Figure 13606-01

Event Code 768 ACCESS 7 module pivot potentiometer (POT5) rotating in the wrong direction. Traction in limp mode and pivot is disabled.

NOTE Event code is logged if the voltage at CA704-7 is changing opposite of pivot command. Figure 13607-01

Event Code 767

•

ACCESS 7 module pivot potentiometer (POT5) voltage changing to quickly.

•

Event code is logged if a voltage at CA704-7 is changing to quickly.

If: Cable is off pulley. –

Then reinstall cable and check for cause.

M4.8-1960-127 03 Rev. 5/09

368

Then correct and recalibrate.

If: Wires are OK. –

NOTE

•

If: Wires are reversed. –

Traction in limp mode and pivot is disabled.

Step 1: Check pivot pot cable.

Step 1: Check POT5 wiring. Wire #570 CA706-A to CA704-9 and wire #722 CA706-B to CA704-8.

Then proceed to Step 2.

Step 2: Check wire #5964 PVP1 to CA702-8 and wire #5963 PVP2 to CA702-7.

•

If: Reversed. –

•

Then correct.

If: Wires are OK.

TSP 6000 Series

Crown 2006 PF15107-99 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

•

If: Forks fail to rotate. –

Then check for contamination and operation of PVP1, PVP2, PVLH, SP1 and RV1.

Then proceed to Step 3.

NOTE

Then a short exists in wire #5964.

Step 3: Connect the DVOM positive lead PVP2 terminal wires #5963 and negative lead to BNEG. Key truck ON and check meter reading.

PVLH failure: Traverse, auxiliary raise and fork extend will be disabled. RV1 failure: Main raise will be disabled.

•

Then replace POT5 and recalibrate pivot function.

•

Then a short exists in wire #5963.

•

Then check POT5 wiring between CA706-A, -B, -C and CA704-7, CA704-8 and CA704-9.

If: Wiring is OK and event code persists. –

If: Approximately 0 V. –

If: Forks rotate and event code persists. –

If: Approximately +BV and event code persists. –

•

Then key truck ON and attempt a pivot.

If: Approximately 0 V. –

•

–

If: Approximately +BV. –

•

Then connect the DVOM positive lead PVP1 terminal with wire #5964 and negative lead to BNEG. Key truck ON and check meter reading.

Then replace POT5 and recalibrate pivot function.

If: Event code persists. –

Then replace ACCESS 7.

Event Code 770 ACCESS 7 module pivot potentiometer (POT5) voltage out of calibration limit. Traction in limp mode.

NOTE Figure 13607-01

Event Code 769 ACCESS 7 module pivot potentiometer (POT5) voltage changing to slowly.

Event code is logged if voltage at CA704-7 is outside the stored calibration value. Step 1: Check for event code 764, if logged address event code 764 before proceeding with event code 770.

•

Traction in limp mode and pivot is disabled.

If: Event code 764 was not logged but POT5 was replaced or adjusted. –

NOTE Event code is logged if a voltage at CA704-7 is changing to slowly.

Then check POT5 wiring and cable. Recalibrate pivot function.

Step 1: Check pivot potentiometer cable.

Step 2: Key truck ON while pressing the up arrow key. Select POT5 A2.1.3 on display menu then pivot forks and view reading on display.

•

If: Cable is off pulley. –

•

–

Then reinstall cable and check for cause.

If: Cable is OK.

Crown 2006 PF15107-100 Rev. 5/09

If: 0.5 to 1.5 V.

•

Then pivot should be fully clockwise.

If: 3.3 to 4.5 V.

TSP 6000 Series

M4.8-1960-128 03 Rev. 5/09

369

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

•

If: Either voltage is out of the above range. –

•

Then pivot should be fully counterclockwise.

Event code is logged should the input signal at CA703-4 and CA703-5 indicate the mast is raising or lowering opposite of command.

Then recalibrate pivot function.

If: Event code persist after calibration. –

NOTE

Step 1: Check ECR3 GRN wire ECR3 to CA710-2, BLU wire CA710-2 to CA708-6, wire #48 CA708-6 to CA703-4. Also WHT wire, ECR3 to CA710-3, BRN wire, CA710-3 to CA708-7, wire #49 to CA703-5.

Then replace POT5.

•

If: Wires are reversed. –

Then correct wiring.

NOTE Figure 13606-01

Auxiliary mast must be lowered fully then raised to reset ECR3 counts.

•

Event Code 771

If: Wiring is OK and event code persists. –

ACCESS 7 module auxiliary height encoder (ECR3) count change with no auxiliary movement. Traction in limp mode and auxiliary lower is disabled.

•

Then replace ECR3.

If: Event code persists. –

Then replace ACCESS 7.

Step 1: Check ECR3 cable.

•

If: Cable is damaged. –

Then repair or replace cable.

Step 2: Check auxiliary mast.

•

If: Auxiliary mast is drifting down. –

•

If: Auxiliary mast is moving up during traverse function. –

•

Then check PVAR.

If: No movement and event code persists. –

•

Then check SVAL and CV3.

Figure 13608-01

Then replace ECR3.

Event Code 773

If: Event code persists. –

ACCESS 7 module auxiliary height encoder (ECR3) CH A or CH B open.

Then replace ACCESS 7.

Traction in limp mode and auxiliary lower is disabled.

Event Code 772 ACCESS 7 module auxiliary height encoder (ECR3) count in wrong direction. Traction in limp mode and auxiliary lower is disabled.

M4.8-1960-129 03 Rev. 5/09

370

Step 1: Check ECR3 GRN wire ECR3 to CA710-2, BLU wire CA710-2 to CA708-6, wire #48 CA708-6 to CA703 -4. WHT wire ECR3 to CA710-3, BRN wire CA710-3 to CA708-7, wire #49 to CA703-5.BLK wire ECR3 to CA710-4, YEL wire CA710-4 to CA708-8, wire #565 CA708-8 to CA703-9.

TSP 6000 Series

Crown 2006 PF15107-101 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 •

–

•

–

If: Wiring is OK.

Then replace ACCESS 7.

Then check for additional event codes.

If: Event code 774 or 775, or both codes, have been logged. –

Then address these first.

Step 2: Disconnect the green and white wires from ECR3 at CA708. Measure the voltage from green and white wires to BNEG. Correct reading should be either 0V or 5 V depending on position of encoder wire rope.

•

If: Voltage measured is not approximately 0 or 5 V (encoder green and white wires must be disconnected from the harness). –

•

ACCESS 7 module auxiliary height encoder (ECR3) power supply out of range. Traction in limp mode and auxiliary lower is disabled.

NOTE Event code is logged should the power supply drop below 4.75 to 5.5 V.

Then replace ACCESS 7.

If: Voltage measured is either 0 or 5 V or wiring between ECR3 and CA703 checks okay. –

Event Code 775

Then replace ECR3.

If: Problem persists. –

•

Then reconnect green wire to blue wire and white wire to brown wire and re-measure the voltage from green and white wires to BNEG.

If: Voltage measured is now greater than 5.5 V. –

•

Figure 13608-01

If: Voltage measured is either 0 or 5 V. –

•

Then replace ECR3.

Then replace ACCESS 7.

Step 1: Connect the DVOM positive lead to CA703-6 and negative lead to BNEG. Key truck ON and check meter reading.

•

Event Code 774

–

ACCESS 7 module auxiliary height encoder (ECR3) power supply wire open. Traction in limp mode and auxiliary lower is disabled.

•

If: Wiring is bad. –

•

–

•

Then repair or replace the wiring.

If: Wiring is OK and event code persists.

•

If: Event code persists.

Crown 2006 PF15107-102 Rev. 5/09

•

Then a short exists in the wiring or ECR3. Check wire #715 CA703-6 to CA708-5, ORG wire CA708-5 to CA710-1, RED wire CA710-1 to ECR3, wire #048 CA703-4 to CA708-6, BLU wire CA708-6 to CA710-2, GRN wire CA710-2 to ECR3, wire #049 CA703-5 to CA708-7, BRN wire CA708-7 to CA710-3, WHT wire CA710-3 to ECR3.

If: Wiring is OK. –

Then replace ECR3.

Then disconnect wire #715 form CA703-6. Check the voltage between CA703-6 and BNEG.

If: 4.75 to 5.5 V. –

Step 1: Check ECR3 RED wire ECR3 to CA710-1, ORG wire CA710-1 to CA 708-5, wire #715 CA708-5 to CA703-6. BLK wire ECR3 to CA710-4, YEL CA710-4 to CA708-8, wire #565 CA708-8 to CA703-9.

•

If: Not 4.75 to 5.5 V.

Then replace ECR3.

If: Not 4.75 to 5.5 V.

TSP 6000 Series

M4.8-1960-131 03 Rev. 5/09

371

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

–

Then replace ACCESS 7.

Figure 13609-01

Figure 13608-01

Event Code 776

Event Code 777

ACCESS 7 module traverse encoder (ECR4) not counting.

ACCESS 7 module traverse encoder (ECR4) count error.

Traction in limp mode and traverse is disabled.

Step 1: Check for other event codes.

Step 1: Auxiliary raise or lower and pivot.

•

If: Additional event codes are present. –

•

Then address them before proceeding with event code 776.

If: No additional event codes are present. –

–

•

Then proceed to step 2.

–

•

–

Then check RED wire ECR4 to CA705-1, wire #716 CA705-1 to CA704-4, BLU wire ECR4 to CA705-2, wire #050 CA705-2 to CA704-10, WHT wire ECR4 to CA705-3, wire #051 CA705-3 to CA704-11 and BLK wire ECR4 to CA705-4, wire #571 CA705-4 to CA704-12.

•

Then check wire #5961 CA702-4 to PVT1 for short to truck frame.

If: Wiring is OK. –

Then check PVT, C+BV1 and C+BV2 also check for contamination.

If: Wiring is OK. –

•

Then check the operation of PVT1, PVLH, SP1 and RV1. Also check for contamination.

Then check PVT, C+BV1 and C+BV2 also check for contamination.

If: Traverse right occurs and event code 777 is logged.

If: Forks traverse. –

•

If: Forks do not traverse.

Then check wire #5960 CA702-3 to PVT2 for short to truck frame.

If: Wiring is OK. –

Step 2: Key truck ON and attempt to traverse.

•

If: Traverse left occurs and event code 777 is logged.

Then replace ECR4.

If: Event code persists.

M4.8-1960-132 03 Rev. 5/09

372

TSP 6000 Series

Crown 2006 PF15107-103 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

•

Then check RED wire TVRS to CA704-5 and BLK wire TVRS to CA704-6.

If: Wiring is OK and event code persists. –

Then replace TVRS.

Step 2: Check ECR4 RED wire ECR4 to CA705-1, wire #716 CA705-1 to CA704-4, BLU wire ECR4 to CA705-2, wire #050 CA705-2 to CA704-10, WHT wire ECR4 to CA705-3, wire #051 CA705-3 to CA704-11 and BLK wire ECR4 to CA705-4, wire #571 CA705-4 to CA704-12.

•

If: Event code persists. –

Then replace ACCESS 7.

Figure 13610-01

Event Code 779 ACCESS 7 module traverse encoder (ECR4) count speed out of range. Figure 13601-01

Traction in limp mode and traverse is disabled.

Event Code 778

Step 1: Check wire #5960 PVT2 to CA702-3 and wire #5961 PVT1 to CA702-4.

ACCESS 7 module traverse encoder (ECR4) reset switch (TVRS) did not toggle.

•

No action taken. Step 1: Recalibrate traverse encoder ECR4.

•

If: Event code clears. –

•

If: Wiring is OK. –

•

Then replace ECR4.

If: Event code persists. –

Then replace ACCESS 7.

Then truck is operation ready.

If: Event code persists. Crown 2006 PF15107-104 Rev. 5/09

TSP 6000 Series

M4.8-1960-133 03 Rev. 5/09

373

ELECTRICAL SYSTEM Event Codes - ACCESS 7 Event Code 780 ACCESS 7 module traverse encoder (ECR4) count direction incorrect. Traction in limp mode and traverse is disabled. Step 1: Check ECR4 BLU wire CA705-2, wire #050 CA705-2 to CA704-10. Also WHT wire CA705-3, wire #051 CA705-3 to CA704-11.

•

If: Wires are reversed. –

•

If: Wiring is OK. –

•

Then check wire #5960 PVT2 to CA702-3 and wire #5961 PVT1 to CA702-4.

Figure 13609-01

If: Wires are reversed. –

•

Then correct wiring and calibrate traverse.

Then correct and calibrate traverse.

If: Wiring is OK. –

Then proceed to Step 2.

Step 2: Connect the DVOM positive lead to PVT1 terminal with wire #5961 and negative lead to BNEG. Key truck ON and check meter reading.

•

If: Approximately +BV. –

•

Then proceed to Step 3

If: 0 V. –

Then check wire #5961 for a short. Repair or replace the wire.

Step 3: Connect the DVOM positive lead to PVT2 terminal with wire #5960 and negative lead to BNEG. Key truck ON and check meter reading.

•

If: Approximately +BV and event code persists. –

•

If: 0 V. –

•

Then replace ECR4 and recalibrate the traverse encoder ECR4.

Then check wire #5960 for a short. Repair or replace the wire.

If: Event code persists. –

Then replace ACCESS 7 and recalibrate the traverse encoder ECR4.

M4.8-1960-134 03 Rev. 5/09

374

TSP 6000 Series

Crown 2006 PF15107-105 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 –

•

If: Cable is damaged. –

•

Then check the auxiliary height encoder (ECR3) cable.

Then repair or replace the cable.

If: Cable OK. –

Then proceed to Step 2.

Step 2: Connect the DVOM positive lead to PVAL terminal with wires #2979 and #2978 and the negative lead to BNEG. Key truck ON and check meter reading.

•

If: Approximately +BV. –

•

If: PVAL is contaminated. –

•

Then recalibrate the PVAL.

If: Event code persists. –

•

Then clean PVAL.

If: Clean. –

•

Then check PVAL for contamination.

Then proceed to Step 3.

If: 0 V. –

Then check wires #2979 and #2978 for a short. Repair or replace the wire

Step 3: Check auxiliary mast height.

•

If: Auxiliary mast is not at maximum height. –

•

Then raise mast to clear fault.

If: Auxiliary mast is at maximum height. –

Then mast must be lowered using the override function in the utilities menu.

TSP 6000 Series

M4.8-1960-135 03 Rev. 5/09

Figure 13601-01

Event Code 781 ACCESS 7 module auxiliary lower velocity fuse trip. Traction in limp mode and auxiliary lower is disabled. Step 1: Check the hydraulic lines and fittings.

•

If: Lines and fittings are damaged. –

•

Then repair or replace lines or fittings.

If: Lines and fittings are OK Crown 2006 PF15107-106 Rev. 5/09

375

ELECTRICAL SYSTEM Event Codes - ACCESS 7 CA704-10, WHT wire ECR4 to CA705-3, wire #051 CA705-3 to CA704-11 and BLK wire ECR4 to CA705-4, wire #571 CA705-4 to CA704-12.

•

If: Event code persists. –

•

Then replace ECR4 and recalibrate.

If: Event code persists. –

Then replace ACCESS 7 and recalibrate the traverse encoder ECR4.

Figure 13609-01

Figure 13601-01

Event Code 782 ACCESS 7 module traverse encoder (ECR4) calibration out of range. Traction in limp mode. Step 1: Recalibrate traverse encoder ECR4.

•

Then check ECR4 RED wire ECR4 to CA705-1, wire #716 CA705-1 to CA704-4, BLU wire ECR4 to CA705-2, wire #050 CA705-2 to

M4.8-1960-137 03 Rev. 5/09

376

Event Code 783 ACCESS 7 module auxiliary height encoder (ECR3) not counting.

If: Event code persists. –

Figure 13608-01

Traction in limp mode and auxiliary lower is disabled.

TSP 6000 Series

Crown 2006 PF15107-107 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 7 NOTE Event code will log if load is to great preventing auxiliary raise movement. Step 1: Key truck OFF then ON.

•

If: Wiring is OK and event code persists. –

Then replace HGTRS2.

Then attempt to raise and lower auxiliary forks.

Then check PVAR, PVLH, SP1, RV1 and LS operation.

Then PVAR, PVLH, SP1, RV1 and LS for contamination.

If: Forks move. –

•

If: PVAR, PVLH, SP1, RV1 and LS operation is OK. –

•

Then check PVLH circuit, refer to event code 751.

Then check HGTRS2 RED wire TB709-1 to CA707-A, wire #5967 CA707-A to CA703-2.

If: Forks do not move. –

•

If: ECR3 wiring is OK. –

If: Event code 751 is not logged. –

•

If: Event code 751 logs. –

•

to CA708-7, wire #49 to CA703-5. BLK wire ECR3 to CA710-4, YEL wire CA710-4 to CA708-8, wire #565 CA708-8 to CA703-9.

Then check ECR3 RED wire ECR3 to CA710-1, ORG wire CA710-1 to CA708-5, wire #715 CA708-5 to CA703-6, GRN wire ECR3 to CA710-2, BLU wire CA710-2 to CA708-6, wire #48 CA708-6 to CA703-4. WHT wire ECR3 to CA710-3, BRN wire CA710-3 to CA708-7, wire #49 to CA703-5. BLK wire ECR3 to CA710-4, YEL wire CA710-4 to CA708-8, wire #565 CA708-8 to CA703-9.

Figure 13611-01

Event Code 785 ACCESS 7 module auxiliary fork height encoder (ECR3) counts out of range.

If: Event code persists.

Traction in limp mode and auxiliary lower is disabled.

–

Step 1: Check F30 in Features Setup, if necessary correct auxiliary mast height.

Then replace ECR3 and recalibrate.

If: Event code persists. –

•

Then replace ACCESS 7.

If: Setup is correct and event code persists. –

Event Code 784

•

ACCESS 7 module auxiliary height reset failed to toggle.

Then truck is service ready.

If: Event code persists. –

Then check ECR3 RED wire ECR3 to CA710-1, ORG wire CA710-1 to CA708-5, wire #715 CA708-5 to CA703-6, GRN wire ECR3 to CA710-2, BLU wire CA710-2 to CA708-6, wire #48 CA708-6 to CA703-4. Also WHT wire

TSP 6000 Series

M4.8-1960-139 03 Rev. 5/09

Step 1: Check ECR3 RED wire ECR3 to CA710-1, ORG wire CA710-1 to CA708-5, wire #715 CA708-5 to CA703-6, GRN wire ECR3 to CA710-2, BLU wire CA710-2 to CA708-6, wire #48 CA708-6 to CA703-4. Also WHT wire ECR3 to CA710-3, BRN wire CA710-3

Crown 2006 PF15107-108 Rev. 5/09

If: Event code clears. –

•

Traction in limp mode.

Then lower the auxiliary forks to minimum height, then raise to 305 mm (12 in).

377

ELECTRICAL SYSTEM Event Codes - ACCESS 7 ECR3 to CA710-3, BRN wire CA710-3 to CA708-7, wire #49 to CA703-5. BLK wire ECR3 to CA710-4, YEL wire CA710-4 to CA708-8, wire #565 CA708-8 to CA703-9.

•

If: Wiring is OK and event code persists. –

•

Then replace ECR3 and recalibrate.

If: Event code persists. –

Then replace ACCESS 7.

Figure 13608-01

Event Code 790 Through Event Code 799 ACCESS 7 module internal fault. Procedures listed apply to event codes 790 through 799. Traction in limp mode, auxiliary raise or lower, traverse, pivot and extend and retract are disabled. Step 1: Reprogram module.

•

If: Event code persists. –

Then replace ACCESS 7.

M4.8-1960-139 03 Rev. 5/09

378

TSP 6000 Series

Crown 2006 PF15107-109 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8

Event Codes - ACCESS 8

resistance between ACCESS 7 CA703-1 and CA703-12

•

Event Code 800

If: 0 Ω. –

ACCESS 8 and ACCESS 5 module CAN time out.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

No action taken. Step 1: Key truck ON and verify the status of ACCESS 5 indicator lights.

•

If: ACCESS 5 indicator lights are ON. –

•

If: ACCESS 5 indicator lights are OFF. –

•

Figure 13547-01

Then check for +BV between CA403-1 and CA403-10 on ACCESS 5.

If: +BV. –

•

Then proceed to Step 2.

Then replace ACCESS 5.

If: 0 V. –

Then check FU8 and wire #505 CA403-1 to CA406 B- and wire #2903 CA403-10 to CA206-9.

•

If: Wire connections and FU8 are OK

•

Then check the wiring between ACCESS 8, CA504-3 and CA504-4 and the platform distribution panel, CA106-3 and CA106-10. Repair or replace wiring as needed.

Step 2: Event code persists, key truck OFF and using a DVOM check the resistance between wire #003 CA402-4 CAN_H and wire #004 CA402-5 CAN_L. Resistance should be 60 Ω.

•

If: 0 Ω.

Event Code 801

–

ACCESS 8 and ACCESS 5 module CAN time out.

Then a short exists between CAN_H and CAN_L. Disconnect CA402 from ACCESS 5 and check the resistance at module pins CA402-3 and CA402-4.

If: 0 Ω. –

•

Figure 13690-01

If: ACCESS 5 indicator lights are ON. –

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other is internal to ACCESS 5. Check the

Crown 2006 PF15107-110 Rev. 5/09

Step 1: Key truck ON and verify the status of ACCESS 5 indicator lights.

•

Then replace ACCESS 8.

If: Infinity 0 Ω. –

No action taken.

•

Then proceed to Step 2.

If: ACCESS 5 indicator lights are OFF. –

TSP 6000 Series

Then check for +BV between CA403-1 and CA403-10 on ACCESS 5.

M4.8-1960-141 03 Rev. 5/09

379

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

If: +BV. –

•

If: 0 V. –

•

Then replace ACCESS 5.

Then check the wiring connected to CA403-1 and CA403-10. Repair or replace as needed.

If: Wire connections are OK. –

Then check the wiring between ACCESS 8, CA504-3 and CA504-4 and the platform distribution panel, CA106-3 and CA106-10. Repair or replace as needed.

Step 2: Event code persists, key truck OFF and using a DVOM check the resistance between CA402-4 CAN_H and CA402-5 CAN_L. Resistance should be 60 Ω.

•

If: 0 Ω. –

•

If: Infinity Ω, reconnect CA402. –

•

Then disconnect CA504 from ACCESS 8 and check the resistance between module pins VA504-3 and CA504-4.

Then replace ACCESS 8.

If: Infinity Ω. –

•

Figure 13117-01

If: 0 Ω. –

•

Then replace ACCESS 5

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other is internal to ACCESS 5. Check the resistance between ACCESS 7, CA703-1 and CA703-12.

Figure 13547-01

Event Code 802 ACCESS 8 and ACCESS 1 module CAN time out.

If: 0 Ω.

No action taken.

–

Step 1: Key truck ON and verify the status of ACCESS 1 indicator lights.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

•

If: ACCESS 1 indicator lights are ON. –

•

If: ACCESS 1 indicator lights are OFF. –

•

380

Then check for +BV between CA304-1 and CA304-2 on ACCESS 1.

If: +BV. –

M4.8-1960-142 03 Rev. 5/09

Then proceed to Step 2.

TSP 6000 Series

Then check connection.

Crown 2006 PF15107-111 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

–

•

–

Then check the wire between ACCESS 8, CA504-3 and CA504-4 and the platform distribution panel, CA106-3 and CA106-10. Repair or replace wiring as needed.

–

Step 2: Event code persists, key truck OFF and using a DVOM check the resistance between wire #027 CA304-4 CAN_H and wire #022 CA304-5 CAN_L. Resistance should be approximately 60 Ω.

If: 0 Ω.

• •

Then a short exists between CAN_H and CAN_L. Disconnect CA304 from ACCESS 1 and check the resistance between module pins CA304-4 and CA304-5.

If: 0 Ω. –

Then replace ACCESS 1.

–

If: Greater than 60 Ω.

–

Then disconnect CA504 from ACCESS 8. Check the resistance between module pins CA504-3 and CA504-4.

If: 0 Ω. –

•

Then check FU7, FU18 and wire #2946 CA304-1 to CA103-12 and wire #512 CA304-2 to CA104-6. Repair or replacing wiring or fuses.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: Wiring and FU7 and FU18 are OK.

–

•

–

If: 0 V.

Then replace ACCESS 8.

If: 120 Ω or greater. –

Then there are two 60 Ω resistors that connect CAN_H and CAN_L together. One is located in the wire harness close to CA703 and the other is internal to ACCESS 5. Check the resistance between connector CA703-1 and CA703-12 on ACCESS 7.

–

If: 0 Ω.

–

Then disconnect CA402 from ACCESS 5. Check the resistance between CA402-4 and CA402-5. Resistance should be 120 Ω.

Figure 13691-01

Event Code 803 ACCESS 8 and ACCESS 4 module CAN time out.

If: 0 Ω

No action taken.

–

Step 1: Key truck ON and verify the status of ACCESS 4 indicator lights.

Then replace ACCESS 5.

If: 120 Ω. Crown 2006 PF15107-112 Rev. 5/09

TSP 6000 Series

M4.8-1960-143 03 Rev. 5/09

381

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

–

•

Then check for +BV between CA314-1 and CA314-2.

• •

Then replace ACCESS 4.

Then disconnect CA402 from ACCESS 5 and check the resistance between CA402-4 and CA402-5. Resistance should be 120 Ω.

If: 0 Ω. –

Then replace ACCESS 5.

If: 120 Ω. –

If: 0 V. –

•

–

If: +BV. –

•

Then proceed to Step 2.

If: 0 Ω.

If: ACCESS 4 indicator lights are OFF. –

•

If: ACCESS 4 indicator lights are ON.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

Then check FU7, FU19 and wire #2950 CA314-1 to CA103-13 and wire #518 CA314-2 to CA101-1. Repair or replace wiring or fuses as needed.

If: Wiring and FU7 and FU18 are OK. –

Then check the wiring between ACCESS 8, CA504-3 and CA504-4 and the platform distribution panel, CA106-3 and CA106-10. Repair or replace wiring as needed. Figure 13194-01

Step 2: Event code persists, key truck OFF and using a DVOM check the resistance between wire #029 CA314-3 CAN_H and wire #028 CA314-4 CAN_L. Resistance should be approximately 60 Ω.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Figure 13547-01

Event Code 804

Then replace ACCESS 4.

If: Greater than 60 Ω.

ACCESS 8 and ACCESS 7 module CAN time out.

–

No action taken.

Then disconnect CA504 from ACCESS 8 and check the resistance between module pins, CA504-3 and CA504-4.

If: 0 Ω. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA314 from ACCESS 4 and check the resistance between module pins, CA314-3 and CA314-4.

•

Then replace ACCESS 8.

382

•

M4.8-1960-144 03 Rev. 5/09

If: ACCESS 7 indicator lights are ON. –

If: 120 Ω or greater. –

Step 1: Key truck ON and verify the status of ACCESS 7 indicator lights.

If: ACCESS 7 indicator lights are OFF. –

•

Then proceed to Step 2.

Then check for +BV between CA703-7 and CA703-8 on ACCESS 7.

If: +BV. –

TSP 6000 Series

Then replace ACCESS 7. Crown 2006 PF15107-113 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

If: 0 V. –

Then check FU7, FU17 or wire #2974 CA703-7 and wire #569 CA703-8. Repair or replace wiring or fuses as needed.

Step 2: Event code persists, key truck OFF and using a DVOM check the resistance between wire #059 CA703-1 CAN_H and wire #058 CA703-12 CAN_L. Resistance should be approximately 60 Ω.

•

If: 0 Ω. –

•

No action taken.

Step 1: Key truck ON and verify the status of ACCESS 1.

•

Then disconnect CA402 from ACCESS 5 and check the resistance between CA402-4 and CA402-5. Resistance should be 120 Ω.

•

If: 0 Ω. –

•

ACCESS 8 and ACCESS 1 module CAN time out.

If: 0 Ω. –

•

Then replace ACCESS 7.

If: Greater than 60 Ω. –

Figure 13641-01

Event Code 805

If: 0 Ω. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA703 from ACCESS 7 and check the resistance between module pins, CA703-1, CA703-4 and CA703-12.

–

Then proceed to step 2

–

If: ACCESS 1 indicator lights are OFF.

–

Then check for +BV between CA304-1 and CA304-2.

If: +BV. –

•

Then replace ACCESS 5.

If: 120 Ω. –

If: ACCESS 1 indicator lights are ON.

If: 0 V. –

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

•

Then replace ACCESS 1.

Then check wire #2946 CA304-1 to CA103-12 and wire #512 CA304-2 to CA104-6 and fuses FU7 and FU18. Repair or replace the wiring or FU7 and FU18 as needed.

If: wiring connections and fuses are OK. –

Then check the wiring between ACCESS 8, CA504-3 and CA504-4 and the platform distribution panel, CA106-3 and CA106-10. Repair or replace wiring as needed.

Step 2: Event code persists, key truck OFF and using a DVOM check the resistance between CAN_H, CA304-4 and CAN_L, CA304-5. Resistance should be 60 Ω.

• Crown 2006 PF15107-114 Rev. 5/09

If: 0 Ω.

TSP 6000 Series

M4.8-1960-146 03 Rev. 5/09

383

ELECTRICAL SYSTEM Event Codes - ACCESS 8 –

•

If: 0 Ω. –

•

Then replace ACCESS 1.

If: Infinity. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA304 from ACCESS 1 and check the resistance between module pins, CA304-4 and CA304-5.

If: 0 Ω. –

Then disconnect CA402 from ACCESS 5 and check the resistance between CA402-4 and CA402-5. Resistance should be 120 Ω.

–

If: 0 Ω.

–

Then replace ACCESS 5.

If: 120 Ω. –

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

Figure 13692-01

Event Code 806 ACCESS 8 and ACCESS 4 module CAN time out. No action taken. Step 1: Key truck ON and verify the status of ACCESS 4 indicator lights.

•

If: ACCESS 4 indicator lights are ON. –

•

If: ACCESS 4 indicator lights are OFF. –

M4.8-1960-146 03 Rev. 5/09

384

Then proceed to Step 2.

TSP 6000 Series

Then check for +BV between CA314-1 and CA314-2. Crown 2006 PF15107-115 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

–

•

Then replace ACCESS 4.

Then replace ACCESS 5.

If: 120 Ω. –

If: 0 V. –

•

–

If: +BV.

Then check FU7, FU19 and wire #2950 CA314-1 to CA103-13 and wire #518 CA314-2 to CA101-1. Repair or replace the wiring or FU7, FU19 as needed.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: Wiring and fuses are OK. –

Then check the wiring between ACCESS 8, CA504-3 and CA504-4 and the platform distribution panel, CA106-3 and CA106-10. Repair or replace wiring as needed.

Step 2: Event code persists, key truck OFF and using a DVOM check the resistance between wire #029 CA314-3 CAN_H and wire #028 CA314-4 CAN_L. Resistance should be approximately 60 Ω.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Then disconnect CA402 from ACCESS 5 and check the resistance between CA402-4 and CA402-5. Resistance should be 120 Ω.

If: 0 Ω. Crown 2006 PF15107-116 Rev. 5/09

Figure 13693-01

Event Code 807 ACCESS 8 and ACCESS 5 module CAN time out. No action taken.

If: 0 Ω. –

•

Then replace ACCESS 8.

If: 120 Ω or greater. –

•

Then disconnect CA504 from ACCESS 8 and check the resistance between module pins, CA504-3 and CA504-4.

If: 0 Ω. –

•

Then replace ACCESS 4.

If: Greater than 60 Ω. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA314 from ACCESS 4 and check the resistance between module pins, CA314-3 and CA314-4.

Step 1: Key truck ON and verify the status of ACCESS 5 indicator lights.

•

If: ACCESS 5 indicator lights are ON. –

TSP 6000 Series

Then proceed to step 2. M4.8-1960-148 03 Rev. 5/09

385

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

If: ACCESS 5 indicator lights are OFF. –

•

If: +BV. –

•

Then replace ACCESS 5.

If: 0 V. –

•

Then check for +BV between CA403-1 and CA403-10 on ACCESS 5.

Then check CA403-1 and CA403-10 wiring. Repair or replace as needed.

If: Wiring and connections are OK. –

Figure 13553-01

Then check wiring between ACCESS 8, CA504-3 and CA504-4 and platform distribution panel, CA106-3 and CA106-10. Repair or replace as needed.

Step 2: Event code persists, key truck OFF and using a DVOM check the resistance between wire #003 CA402-4 CAN_H and wire #004 CA402-5 CAN_L. Resistance should be approximately 60 Ω.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Travel, steering, main raise or lower are disabled. Step 1: Replace ACCESS 8.

Event Code 821 ACCESS 8 module 5 V power supply out of regulation. Full traction, main raise or lower are disabled, limp hydraulics is enabled

Then disconnect CA504 from ACCESS 8 and check the resistance between module pins, CA504-3 and CA504-4.

•

–

•

Then replace ACCESS 8.

If: Not between 44 and 52 V. Then check FU7, FU18, wiring and condition of battery. Wire #2995 CA504-1 to CA318-6 and wire #520 CA504-2 to CA505-1.

If: Between 44 and 52 V. –

Then replace ACCESS 8.

If: Infinity Ω. –

•

Then replace ACCESS 5.

If: 0 Ω. –

ACCESS 8 module internal fault.

Step 1: Connect the DVOM positive lead to CA504-1 and the negative lead to CA504-2, key truck ON and check the voltage reading.

If: Greater than 60 Ω. Reconnect CA402. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA402 from ACCESS 5 and check the resistance between module pins, CA402-3 and CA402-4.

Event Code 816

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other one is internal to ACCESS 5. Check the resistance between CA703-1 and CA703-12 on ACCESS 7.

If: 0 Ω. –

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

M4.8-1960-151 03 Rev. 5/09

386

Event Code 822 ACCESS 8 module 15 V power supply out of regulation. Full traction, main raise, lower are disabled, limp hydraulics is enabled. Step 1: Connect the DVOM positive lead to CA504-1 and negative lead to CA504-2, key truck ON and check the voltage reading.

TSP 6000 Series

Crown 2006 PF15107-117 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

–

•

If: Not between 44 and 52 V. Then check FU7, FU18, wiring and condition of battery. Wire #2995 CA504-1 to CA318-6 and wire #520 CA504-2 to CA505-1.

–

•

If: Between 44 and 52 V. –

If: Between 4.75 and 5.5 V. Then problem is in the seat tube harness between CA508 and CA503.

If: Not between 4.75 and 5.5 V. –

Then replace ACCESS 8.

Figure 13642-01

Event Code 823 ACCESS 8 module steer encoder ECR2 power supply out of regulation. Full traction, main raise are disabled, limp hydraulics is enabled. Step 1: Connect the DVOM positive lead to CA503-5 and negative lead to CA503-6, key truck ON and check the voltage reading.

•

If: Not between 4.75 and 5.5 V. –

•

Then a short exists in the wiring to ECR2 or internal to ECR2. Check WHT wire ECR2 to CA508-5, wire #038 to CA503-7, BLK wire ECR2 to CA508-6, wire #521 to CA503-6, BLU wire ECR2 to CA508-7, wire #039 CA508-7 to CA503-8 and RED wire ECR2 to CA508-8, wire #710 CA508-8 to CA503-5.

If: Wiring is OK and event code persists. –

Figure 13694-01

Event Code 824

If: Between 4.75 and 5.5 V. –

•

Then disconnect CA508 in the left armrest (CA508 connects ECR 1 & 2 to seat tube harness), connect the positive lead to CA503-5 and negative lead to CA503-6, key truck ON and check the voltage.

ACCESS 8 module optical switch board FS/RS power supply out of regulation. Full traction and main raise are disabled, limp hydraulics is enabled. Step 1: Connect the DVOM positive lead to CA501-7 (optical switch board 5 V) and negative lead to CA501-8, key truck ON and check the voltage reading.

•

Then replace ECR2.

–

If: Not between 4.75 and 5.5 V. –

Then remove wire #710 from CA503-5 and check the voltage on CA503-5. Crown 2006 PF15107-118 Rev. 5/09

If: Between 4.75 and 5.5 V.

•

Then check VIO wire CA501-7 to optical board and GRN wire CA501-8 to optical board.

If: Not between 4.75 and 5.5 V.

TSP 6000 Series

M4.8-1960-152 03 Rev. 5/09

387

ELECTRICAL SYSTEM Event Codes - ACCESS 8 –

•

If: Between 4.75 and 5.5 V. –

CA508-3, wire #031 CA508-3 to CA503-12 and RED wire ECR1 to CA508-4, wire #711 CA508-4 to CA503-9.

Then disconnect VIO wire from CA501-7 then check the voltage between CA501-7 and CA501-8.

Then a short exists in the optical board, replace the optical board.

–

•

If: Not between 4.75 and 5.5 V. –

If: Wiring is OK and event code persists.

If: Not between 4.75 and 5.5 V. –

Then replace ACCESS 8.

•

Then remove wire #711 from CA503-9 and check the voltage on CA503-9.

If: Between 4.75 and 5.5 V. –

•

Then replace ECR1.

Then the problem is in the seat tube harness between CA508 and CA503.

If: Not between 4.75 and 5.5 V. –

Then replace ACCESS 8.

Figure 13695-01

Event Code 825 ACCESS 8 module steer encoder ECR1 power supply out of regulation. Full traction, main raise is disabled, limp hydraulics is enabled. Step 1: Connect the DVOM positive lead to CA503-9 and negative lead to CA503-10, key truck ON and check the voltage reading.

•

If: Not between 4.75 and 5.5 V. –

•

Then disconnect CA508 in the left armrest (CA508 connects ECR 1 & 2 to seat tube harness), connect the positive lead to CA503-9 and negative lead to CA503-10, key truck ON and check voltage.

If: Between 4.75 and 5.5 V. –

Then a short exists in the wiring to ECR1 or internal to ECR1. Check WHT wire ECR1 to CA508-1, wire #030 CA508-1 to CA503-11, BLK wire ECR1 to CA508-2, wire #542 CA508-2 to CA503-10, BLU wire ECR1 to

M4.8-1960-154 03 Rev. 5/09

388

Figure 13694-01

Event Code 836 ACCESS 8 module traction potentiometer POT1 out of electrical limits. Traction is disabled.

TSP 6000 Series

Crown 2006 PF15107-119 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 NOTE Event code is logged when POT1 voltage at CA502-2 is either above or below electrical limit. Step 1: Key truck ON while pressing the up arrow key. Select POT1 A2.3.2 on display menu, view the reading on the display.

•

If: 5 V or greater. –

•

Then replace POT1 and calibrate.

•

–

Then check POT2 RED wire POT2-1 to CA502-10, WHT wire POT2-2 to CA502-11 and BLK wire POT2-3 to CA502-12.

If: Wiring is OK and event code persists. –

If: Wiring is OK and event code persists.

Then replace POT2 and calibrate.

If: Below 0.7 V. –

Then check POT1 RED wire POT1-3 to CA502-1, WHT wire POT1-2 to CA502-2 and BLK wire POT1-1 to CA502-3.

Then control handle is in full main lower position.

If: Correct POT2 voltage is confirmed and event code persists. –

If: Below 0.7 V. –

•

Then control handle is in full reverse position.

Then control handle is in full main raise position.

If: Between 3.4 to 4.3 V. –

Then control handle is in full forward position.

Then control handle is in center position.

If: Between 0.7 to 1.5 V. –

•

Then replace POT2 and calibrate.

If: Between 2.1 and 2.9 V.

Then control handle is in center position.

If: Correct POT1 voltage is confirmed and event code persists. –

•

Then check POT2 RED wire POT2-1 to CA502-10, WHT wire POT2-2 to CA502-11 and BLK wire POT2-3 to CA502-12.

If: Wiring is OK and event code persists. –

•

If: Between 3.4 to 4.3 V. –

•

–

Then replace POT1 and calibrate.

If: Between 0.7 to 1.5 V. –

If: 5 V or greater. –

If: Between 2.1 and 2.9 V. –

•

If: Wiring is OK and event code persists. –

•

Then check POT1 RED wire POT1-3 to CA502-1, WHT wire POT1-2 to CA502-2 and BLK wire POT1-1 to CA502-3

Step 1: Key truck ON while pressing the up arrow key. Select POT2 A2.3.3 on the display menu, view the reading on the display.

Then replace POT2 and calibrate.

Event Code 838

Then replace POT1 and calibrate.

Event Code 837

ACCESS 8 module POT3 auxiliary raise, lower potentiometer out of electrical limits.

ACCESS 8 module traction potentiometer POT2 out of electrical limits.

Auxiliary raise or lower are disabled.

NOTE

Main raise, lower and full traction is disabled.

Event code is logged when POT3 voltage at CA504-8 is either above or below electrical limit.

NOTE Event code is logged when POT2 voltage at CA502-11 is either above or below electrical limit.

Step 1: Key truck ON while pressing the up arrow key. Select POT3 A2.3.4 on the display menu, view the reading on the display.

• Crown 2006 PF15107-120 Rev. 5/09

If: 5 V or greater.

TSP 6000 Series

M4.8-1960-156 03 Rev. 5/09

389

ELECTRICAL SYSTEM Event Codes - ACCESS 8 –

•

If: Wiring is OK and event code persists. –

•

–

Then replace POT3 and calibrate.

Event Code 839

Traverse and fork extend or retract are disabled.

Then check POT3 RED wire POT3-1 to CA507-5, wire #713 CA507-5 to CA504-7 WHT wire POT3-2 to CA507-6, wire #105 CA507-6 to CA504-8 and BLK wire POT3-3 to CA507-7 and wire #544 CA507-7 to CA504-9.

If: Wiring is OK and event code persists.

Figure 13696-01

ACCESS 8 module POT4 traverse potentiometer out of electrical limits.

Then replace POT3 and calibrate.

If: Below 0.7 V. –

•

Then control handle is in full auxiliary lower position.

If: Correct POT3 voltage is confirmed and event code persists. –

•

Then control handle is in full auxiliary raise position.

If: Between 3.4 to 4.3 V. –

•

Then control handle is in center position.

If: Between 0.7 to 1.5 V. –

•

Then replace POT3 and calibrate.

If: Between 2.1 and 2.9 V. –

•

Then check POT3 RED wire POT3-1 to CA507-5, wire #713 CA507-5 to CA504-7 WHT wire POT3-2 to CA507-6, wire #105 CA507-6 to CA504-8, BLK wire POT3-3 to CA507-7 and wire #544 CA507-7 to CA504-9.

NOTE Event code is logged when POT4 voltage at CA502-5 is either above or below electrical limit. Step 1: Key truck ON while pressing the up arrow key. Select POT4 A2.3.5 on the display menu, view the reading on the display.

•

If: 5 V or greater. –

•

If: Below 0.7 V. –

•

390

Then control handle is in center position.

If: Between 0.7 and 1.5 V. –

M4.8-1960-157 03 Rev. 5/09

Then check POT4 Red wire POT4 to CA502-4. WHT wire POT4-2 to CA502-5. BLK wire POT4 to CA502-6.

If: Between 2.1 and 2.9 V. –

•

Then check POT4 RED wire POT4-1 to CA502-4, WHT wire POT4-2 to CA502-5 and BLK wire POT4-3 to CA502-6.

TSP 6000 Series

Then control handle is in full traverse left position.

Crown 2006 PF15107-121 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

–

•

–

If: Between 3.4 and 4.3 V. Then control handle is in full traverse right position.

•

If: 2.3 V and event code persists. –

If: POT4 wiring and voltage is correct and event code persist. –

•

Then replace POT4 and calibrate.

•

Event Code 840

Limp traction, main and auxiliary raise or lower, traverse, fork extend or retract and pivot are disabled.

•

Then HPSL circuit is OK.

If: OL. –

•

Then replace HPSR.

If: Approximately 1.1 V. –

ACCESS 8 module hand presence switch HPSL (left hand presence switch) or HPSR (right hand presence switch) photo diode open.

Then HPSR circuit is OK. To check HPSL circuit set the DVOM on diode check and connect the positive lead to wire #2964 CA504-10 and the negative lead on CA506-1.

If: OL. –

Figure 13696-01

Then an open or incorrectly wired condition exists in the photo diode circuit. Using a DVOM set on diode check connect the positive lead to ORG wire CA506-1 and the negative lead to GRN wire CA501-6.

If: Approximately 1.1 V. –

•

Then replace ACCESS 8.

If: OL. –

•

Then check wire 2966 CA504-6 to CA507-1, VIO wire CA507-1 to HPSL, wire #2964 to CA507-3 and ORG wire CA507-3 to HPSL.

If: Wiring is OK and event code persists. –

•

Then HPSL and HPSR are wired correctly.

Then replace HPSL

If: 1.1 V and event code persists. –

Then replace ACCESS 8.

NOTE HPSL and HPSR are wired in series. Tests are performed with truck power OFF and connectors disconnected to allow access to indicated terminals. To obtain accurate results meter leads must be orientated as indicated in each step. Step 1: Check for continuity and proper diode orientation of both photodiodes. Set the DVOM on diode check then connect the positive lead to wire #2964 CA504-10 and negative lead to wire #2966 CA504-6. DVOM should show the two diodes forward biased by displaying approximately 2.3 V.

•

If: 2.3 V.

Crown 2006 PF15107-122 Rev. 5/09

TSP 6000 Series

M4.8-1960-158 03 Rev. 5/09

391

ELECTRICAL SYSTEM Event Codes - ACCESS 8 –

•

If: POT1 is not within limit. –

•

Then replace the switch.

Then calibrate POT1.

If: Calibration is not effective. –

Then replace POT1.

Event Code 842 ACCESS 8 module traction potentiometer (POT1) does not match reverse switch (RS). Limp traction enabled.

NOTE Inadequate handle calibration could be the cause. Figure 13697-01

Event Code 841

Step 1: Key truck ON while pressing up arrow key. Select POT1 A2.3.2, RS A2.3.8 on the display menu, view the reading and verify proper operation.

•

–

ACCESS 8 module traction potentiometer (POT1) does not match forward switch (FS). Limp traction is enabled.

NOTE Inadequate handle calibration could be the cause. Step 1: Key truck ON while pressing the up arrow key. Select POT1 A2.3.2, FS A2.3.7 on display menu, view the reading and verify proper operation.

•

If: Operation is not correct. –

Then check FS wiring. FS switch (yellow sleeving) mounted nearest handle grip. F stamped on actuator that passes between optic sensors.

FS, POT1 operation: input status of FS switch with right multi task handle in neutral should be open as indicated on display A2.3.7. POT1 value on display A2.3.2 should be between 2.1 to 2.9 V. Moving the right multi task handle to full forward position should toggle FS switch closed A2.3.7. POT1 value A2.3.2 should be between 0.7 to 1.5 V.

•

Then check RS wiring. RS switch (black sleeving) mounted nearest casting. R stamped on actuator that passes between optic sensors.

FS, POT1 operation: input status of RS switch with right multi task handle in neutral should be open as indicated on display A2.3.8. POT1 value on display A2.3.2 should be between 2.1 V to 2.9 V. Moving the right multi task handle to full forward position should toggle RS switch closed A2.3.8. POT1 value A2.3.2 should be between 0.7 to 1.5 V.

•

If: Readings are not as shown. –

Then check switch.

•

If: Switch is bad.

•

Then replace the switch.

•

If: POT1 is not within limit. –

•

Then calibrate POT1.

If: Calibration is not effective. –

Then replace POT1.

If: Readings are not as shown. –

•

If: Operation is not correct.

Then check switch.

If: Switch is bad.

M4.8-1960-159 03 Rev. 5/09

392

TSP 6000 Series

Crown 2006 PF15107-123 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 Event Code 843

NOTE

ACCESS 8 module forward switch (FS) and reverse switch (RS) indicate both closing at the same time. Limp traction is enabled. Step 1: Key truck ON while pressing the up arrow key. Select FS A2.3.7, RS A2.3.8 on display menu, and check the switch status with right multi task handle in neutral position.

•

If: Either FS or RS is closed use that switch. –

•

Then proceed to Step 2.

If: Selected switch display changes to open. –

•

If: Event code 844 is logged. –

•

Then replace ACCESS 8.

If: Event code clears. –

Step 2: Check optical switch function. Disconnect BLK wire from CA501-10 for FS test or WHT wire from CA501-9 for RS test.

•

Step 1: ACCESS 8 disconnect and insulate wire #5985 CA502-7. ACCESS 4 CA314-5 place a jumper across thermostat TS3 and key truck ON.

Then proceed to Step 2.

If: Both FS and RS are closed choose either switch. –

Event code is logged if excessive current flows through module driver CA502-7.

Then a short exists in wiring. Reconnect wire #5985 and proceed to Step 2.

Step 2: Key truck OFF. Disconnect CA510 and CA511 connectors going to EDS switch heater. Using a DVOM check the resistance across the two connectors, resistance should be greater than 50 Ω.

•

If: Less than 50 Ω. –

Then replace the heater.

Then replace switch and calibrate.

If: Selected switch display is closed. –

Then replace ACCESS 8.

Figure 13698-01 Figure 13695-01

Event Code 844 ACCESS 8 module cold condition heater driver current to high. No action taken.

Crown 2006 PF15107-124 Rev. 5/09

Event Code 845 ACCESS 8 module left hand presence switch (HPSL) open receiver. Traverse and fork extend or retract disabled. Step 1: Check the wiring from HPSL receiver to ACCESS 8. VIO wire HPSL to CA507-1, wire #2966

TSP 6000 Series

M4.8-1960-160 03 Rev. 5/09

393

ELECTRICAL SYSTEM Event Codes - ACCESS 8 CA507-1 to CA504-6, BLK wire HPSL to CA507-2 and wire #2965 CA507-2 to CA504-5.

•

If: Wiring is OK. –

•

If: 220 kΩ or less. –

•

Then HPSL receiver is OK.

If: Higher than 220 kΩ. –

•

Then disconnect CA504 from ACCESS 8. Connect the DVOM positive lead to the GRN wire CA504-6 and the negative lead to VIO wire CA504-5.

Then replace HPSL.

If: Event code persists. –

Then replace ACCESS 8.

Event Code 846

Figure 13697-01

ACCESS 8 module right hand presence switch (HPSR) open receiver.

Event Code 847

Limp traction enabled, main raise, auxiliary raise or lower and pivot are disabled.

ACCESS 8 module steer tiller encoders (ECR1 and ECR2) turn rate error.

Step 1: Check the wiring from HPSRL receiver to ACCESS 8. VIO wire HPSR to CA501-3 and BLK wire HPSR to CA501-4.

Full traction is disabled.

•

If: Wiring is OK. –

•

If: 220 kΩ or less. –

•

Then HPSR receiver is OK.

If: Higher than 220 kΩ. –

•

Then disconnect CA501 from ACCESS 8. Connect the DVOM positive lead to BLK wire CA501-4 and the negative lead to VIO wire CA501-3.

Then replace HPSR.

NOTE Event code is logged if the turn rate between ECR1 and ECR2 is not equal. This could be due to loss of power or channel A or B of either encoder. Step 1: Key truck ON while pressing the up arrow key. Select ECR1 A2.3.1 on the display menu and view the reading on the display.

•

–

•

Then replace ACCESS 8.

If: ECR2 operates properly. –

394

Then proceed to Step 3.

Step 2: Select ECR2 A2.3.1 on the display menu and view the reading on the display.

•

M4.8-1960-162 03 Rev. 5/09

Then proceed to Step 2.

If: ECR1 does not operate properly. –

If: Event code persists. –

If: ECR1 operates properly.

TSP 6000 Series

Then check the WHT wire ECR2 to CA508-5, wire #038 CA508-5 to CA503-7, BLK wire ECR2 to CA508-6, wire #521 CA508-6 to CA503-6, BLU wire ECR2 to CA508-7, wire

Crown 2006 PF15107-125 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 #039 CA508-7 to CA503-8, RED wire ECR2 to CA508-8 and wire #710 CA508-8 to CA503-5.

•

Then proceed to Step 3.

Step 3: Key truck OFF and inspect the steer tiller for slippage between ECR1 or ECR2 and the steer tiller for damaged or broken wires from ECR1 or ECR2 to seat tube wire harness CA508.

•

–

•

Then repair or replace as needed.

Then inspect all of the wiring from CA508-1 through -8 to CA503-5 through -12.

If: Wiring is OK and event code persists.

–

•

Then key truck OFF and disconnect CA503 from ACCESS 8. Key truck ON and check for 5V between pins CA503-9 and CA503-10.

If: Voltage does vary between 0.5 to 4.5 V.

–

Then replace ECR1.

•

Step 5: ECR2 test, disconnect CA508. Connect the DVOM positive lead to CA508-8 wire #710 and the negative lead to CA508-6 wire #521, check for 5 V.

•

Then replace ECR2.

If: Voltage does vary between 0.5 to 4.5 V. –

Then replace ACCESS 8.

Then proceed to Step 5.

Then proceed to Step 7.

If: Voltage does not vary between 0.5 to 4.5 V.

If: Event code persists. –

Then replace ECR1.

Step 7: Check ECR2 CH A counts. Connect the DVOM positive lead to CA503-7 and the negative lead to CA503-6. Turn the steer tiller slowly.

•

If: Not 4.75 to 5.5 V.

Then check ECR1 CH B counts. Connect the DVOM positive lead to CA503-12 and the negative lead to CA503-10. Turn the steer tiller slowly.

If: Voltage does not vary between 0.5 to 4.5 V.

–

If: 4.75 to 5.5 V.

–

•

Then replace ECR1.

If: Voltage does vary between 0.5 to 4.5 V. –

If: Not 4.75 to 5.5 V.

–

•

Then reconnect CA508 and check for 4.75 to 5.5 V between CA508-4 and CA508-5.

If: Voltage does not vary between 0.5 to 4.5 V. –

•

Then proceed to Step 4.

If: 4.75 to 5.5 V.

–

•

Then replace ACCESS 8.

If: No slippage.

–

•

Then replace ECR2.

If: Not 4.75 to 5.5 V. –

Step 4: ECR1 test, disconnect CA508. Connect the DVOM positive lead to CA508-4 wire #711 and the negative lead to CA508-2 wire #542, check for 4.75 to 5 V.

•

If: 4.75 to 5.5 V. –

•

Then key truck OFF and disconnect CA503 from ACCESS 8. Key truck ON and check for 5 V between pins CA503-5 and CA503-6.

Step 6: Check ECR1 CH A counts. Connect the DVOM positive lead to CA503-11 and the negative lead to CA503-10. Turn the steer tiller slowly.

–

•

If: Slippage or wiring problems. –

•

If: Not 4.75 to 5.5 V. –

If: ECR2 does not operate properly. –

•

Then check ECR2 CH B counts. Connect the DVOM positive lead to CA503-8 and the negative lead to CA503-6. Turn the steer tiller slowly.

If: Voltage does not vary between 0.5 to 4.5 V. –

Then replace ECR2.

If: 4.75 to 5.5 V. –

Then reconnect CA508 and check for 4.75 to 5.5V between CA508-8 and CA508-6.

Crown 2006 PF15107-126 Rev. 5/09

TSP 6000 Series

M4.8-1960-163 03 Rev. 5/09

395

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

If: ECR2 operates as specified. –

•

If: Slippage or wiring problems. –

•

Then problem may be due to wiring or slippage between ECR1 and ECR2. Check for slippage also all the wiring from CA508-1 through CA508-8 to CA503-5 through CA503-12.

Then repair or replace as needed.

If: ECR2 does not operate as specified. –

Then proceed to Step 3.

Step 3: Check ECR1, disconnect CA508. Connect the DVOM positive lead to CA508-4 wire #711 and the negative lead to CA508-2 wire #542, check for 5 V.

•

If: 4.75 to 5.5 V. –

•

If: Not 4.75 to 5.5 V. –

• Figure 13694-01

ACCESS 8 module ECR1 and ECR2 (steer tiller encoders) direction of rotation error.

NOTE Event code is logged if direction of count between ECR1 and ECR2 is not equal. This could be due to the loss of power or channel A or B of either encoder. Step 1: Key truck ON while pressing the up arrow key. Select ECR1 A2.3.1 on the display menu and view the reading.

• •

•

–

•

Then proceed to Step 3.

M4.8-1960-164 03 Rev. 5/09

Then key truck OFF and disconnect CA503 from ACCESS 8. Key truck ON and check for 5 V between pins CA503-5 and CA503-6.

If: 4.75 to 5.5 V. –

•

Then reconnect CA508 and check for 4.75 to 5.5 V between CA508-8 and CA508-6.

If: Not 4.75 to 5.5 V.

Then proceed to Step 2.

Step 2: Select ECR2 A2.3.1 on the display menu, view the reading.

396

If: 4.75 to 5.5 V.

–

If: ECR1 does not operate as specified.

Then proceed to Step 4.

Step 4: Check ECR2, disconnect CA508. Connect the DVOM positive lead to CA508-8 wire #710 and the negative lead to CA508-6 wire #521, check for 5 V.

If: ECR1 operates as specified. –

Then replace ACCESS 8.

If: Event code persists. –

Traction and steering are disabled.

Then replace ECR1.

If: Not 4.75 to 5.5 V. –

•

Then key truck OFF and disconnect CA503 from ACCESS 8. Key truck ON and check for 5 V between pins CA503-9 and CA503-10.

If: 4.75 to 5.5 V. –

•

Event Code 848

Then reconnect CA508 and check for 4.75 to 5.5 V between CA508-4 and CA508-5.

Then replace ECR2.

If: Not 4.75 to 5.5 V.

TSP 6000 Series

Crown 2006 PF15107-127 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 –

Then replace ACCESS 8.

Step 5: Check ECR1 CH A counts. Connect the DVOM positive lead to CA503-11 and the negative lead to CA503-10. Turn the steer tiller slowly.

•

If: Voltage does not vary between 0.5 to 4.5 V. –

•

If: Voltage does vary between 0.5 to 4.5 V. –

•

Then check ECR1 CH B counts. Connect the DVOM positive lead to CA503-12 and the negative lead to CA503-10. Turn the steer tiller slowly.

If: Voltage does not vary between 0.5 to 4.5 V. –

•

Then replace ECR1.

If: Voltage does vary between 0.5 to 4.5 V. –

Then proceed to Step 6.

Step 6: Check ECR2 CH A counts. Connect the DVOM positive lead to CA503-7 and the negative lead to CA503-6. Turn the steer tiller slowly.

•

If: Voltage does not vary between 0.5 to 4.5 V. –

•

Figure 13694-01

If: Voltage does vary between 0.5 to 4.5 V. –

•

Then replace ECR2.

Then check ECR2 CH B counts. Connect the DVOM positive lead to CA503-8 and the negative lead to CA503-6. Turn the steer tiller slowly.

If: Voltage does not vary between 0.5 to 4.5 V. –

Event Code 849 ACCESS 8 module steer tiller encoders (ECR1 and ECR2) direction of rotation error. Traction and steering disabled.

Then replace ECR2.

NOTE Event code is logged if direction of the count between ECR1 and ECR2 is not equal. This could be due to a loss of power or channel A or B of either encoder. Step 1: Key truck ON while pressing the up arrow key. Select ECR1 A2.3.1 on the display menu and view the reading.

•

If: ECR1 operates as specified. –

•

Then proceed to Step 2.

If: ECR1 does not operate as specified. –

Then proceed to Step 3.

Step 2: Select ECR2 A2.3.1 on the display menu and the view reading. Crown 2006 PF15107-128 Rev. 5/09

TSP 6000 Series

M4.8-1960-165 03 Rev. 5/09

397

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

–

•

Then problem may be due to wiring or slippage between ECR1 and ECR2. Check for slippage and all the wiring from CA508-1 through -8 to CA503-5 through -12.

•

If: ECR2 does not operate as specified. –

•

If: Voltage does not vary between 0.5 to 4.5 V. –

Then replace ECR2.

Then reconnect CA508 and check for 4.75 to 5.5 V between CA508-8 and CA508-6.

Then key truck OFF and disconnect CA503 from ACCESS 8. Key truck ON and check for 5 V between pins CA503-5 and CA503-6.

If: 4.75 to 5.5 V. –

•

Then check ECR2 CH B counts. Connect the DVOM positive lead to CA503-8 and the negative lead to CA503-6. Turn the steer tiller slowly.

If: Not 4.75 to 5.5 V. –

•

If: Voltage does vary between 0.5 to 4.5 V.

Then replace ACCESS 8.

Then proceed to Step 4.

Then replace ECR2.

If: 4.75 to 5.5 V. –

•

If: Voltage does not vary between 0.5 to 4.5 V.

–

Step 4: Check ECR2, disconnect CA508. Connect the DVOM positive lead to CA508-8 wire #710 and the negative lead to CA508-6 wire #521, check for 5 V.

•

If: Event code persists. –

Then proceed to Step 6.

Step 6: Check ECR2 CH A counts. Connect the DVOM positive lead to CA503-7 and the negative lead to CA503-6. Turn the steer tiller slowly.

–

Then replace ECR1.

If: Voltage does vary between 0.5 to 4.5 V. –

If: Not 4.75 to 5.5 V. –

•

Then key truck OFF and disconnect CA503 from ACCESS 8. Key truck ON and check for 5 V between pins CA503-9 and CA503-10.

•

If: 4.75 to 5.5 V. –

•

Then reconnect CA508 and check for 4.75 to 5.5 V between CA508-4 and CA508-5.

Then check ECR1 CH B counts. Connect the DVOM positive lead to CA503-12 and the negative lead to CA503-10. Turn the steer tiller slowly.

If: Voltage does not vary between 0.5 to 4.5 V. –

If: Not 4.75 to 5.5 V. –

•

Then replace ECR1.

If: Voltage does vary between 0.5 to 4.5 V.

Then proceed to Step 3.

If: 4.75 to 5.5 V. –

If: Voltage does not vary between 0.5 to 4.5 V.

–

Step 3: Check ECR1, disconnect CA508. Connect the DVOM positive lead to CA508-4 wire #711 and the negative lead to CA508-2 wire #542, check for 5 V.

•

–

Then repair or replace as needed.

Then replace ACCESS 8.

Step 5: Check ECR1 CH A counts. Connect the DVOM positive lead to CA503-11 and the negative lead to CA503-10. Turn the steer tiller slowly.

If: Slippage or wiring problems. –

•

–

If: ECR2 operates as specified.

Then replace ECR2.

If: Not 4.75 to 5.5 V.

M4.8-1960-167 03 Rev. 5/09

398

TSP 6000 Series

Crown 2006 PF15107-129 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 –

Then insure they are correctly installed and connected and have the correct software installed.

Step 2: Check the resistance of the CAN lines. There are two CAN terminating resistors, one internal to ACCESS 5 and one in the wire harness near CA703. Key truck OFF and connect the DVOM meter leads to TP4 and TP5 on the power unit distribution panel. The resistance should be 60 Ω.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Then leave DVOM meter leads connected and disconnect CA402 from ACCESS 5.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 120 Ω. –

Then resistor in ACCESS 5 is shorted. Replace ACCESS 5.

Figure 13694-01

Event Code 850 Through Event Code 852

Figure 13547-01

ACCESS 8 or ACCESS 5 module CAN receiving error. Procedures listed apply to Event Codes 850 through 852. No truck functions are disabled. Event code 850: ACCESS 5 receiving data packets too fast. Event code 851: ACCESS 5 receiving short data packets. Event code 852: ACCESS 5 receiving long data packets. Step 1: Verify the correct modules are in place on the truck.

•

If: Any new modules have recently been installed on the truck.

Crown 2006 PF15107-130 Rev. 5/09

Event Code 853 Through Event Code 855 ACCESS 8 and ACCESS 6 module CAN receiving error. Procedures listed apply to Event Codes 853 through 855. No action taken. Event code 853: ACCESS 6 receiving data packets too fast. Event code 854: ACCESS 6 receiving short data packets. Event code 855: ACCESS 6 receiving long data packets. Step 1: Verify correct modules are in place on the truck.

TSP 6000 Series

M4.8-1960-168 03 Rev. 5/09

399

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

If: Any new modules have recently been installed on the truck.

Step 1: Verify correct modules are in place on the truck.

–

•

Then insure they are correctly installed and connected and have the correct software installed.

•

If: 0 Ω. –

•

–

•

Then resistor in ACCESS 5 is shorted. Replace ACCESS 5.

•

Then leave DVOM meter leads connected and disconnect CA402 from ACCESS 5.

If: 0 Ω. –

If: 120 Ω. –

If: 0 Ω. –

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

Then insure they are correctly installed and connected and have the correct software installed.

If: 0 Ω. –

•

Then leave DVOM meter leads connected and disconnect CA402 from ACCESS 5.

If: Any new modules have recently been installed on the truck.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 120 Ω. –

Then resistor in ACCESS 5 is shorted. Replace ACCESS 5.

Figure 13547-01

Event Code 856 Through Event Code 859

Figure 13547-01

ACCESS 8 and ACCESS 1 module receiving error. Procedures listed apply to Event Codes 856 through 859. No action taken. Event code 856: ACCESS 1 receiving data packets too fast. Event code 857: ACCESS 1 receiving short data packets. Event code 858: ACCESS 1 receiving long data packets.

M4.8-1960-170 03 Rev. 5/09

400

Event Code 860 Through Event Code 863 ACCESS 8 and ACCESS 4 module CAN receiving error. Procedures listed apply to Event Codes 860 through 863. No action taken. Event code 860: ACCESS 4 receiving data packets too fast. Event code 861: ACCESS 4 receiving short data packets.

TSP 6000 Series

Crown 2006 PF15107-131 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 Event code 862: ACCESS 4 receiving longdata packets.

Event code 864: ACCESS 7 receiving data packets too fast.

Event code 863: ACCESS 4 receiving duplicate ID.

Event code 865: ACCESS 7 receiving short data packets.

Step 1: Verify correct modules are in place on the truck.

•

If: Any new modules have recently been installed on the truck. –

Then insure they are correctly installed and connected and have the correct software installed.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Then leave DVOM meter leads connected and disconnect CA402 from ACCESS 5.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 120 Ω. –

Then resistor in ACCESS 5 is shorted. Replace ACCESS 5.

Event code 866: ACCESS 7 receiving long data packets. Event code 867: ACCESS 7 receiving duplicate ID. Step 1: Verify correct modules are in place on the truck.

•

If: Any new modules have recently been installed on the truck. –

Then insure they are correctly installed and connected and have the correct software installed.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Then leave DVOM meter leads connected and disconnect CA402 from ACCESS 5.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 120 Ω. –

Then resistor in ACCESS 5 is shorted. Replace ACCESS 5.

Figure 13547-01

Event Code 864 Through Event Code 867 ACCESS 8 and ACCESS 7 module CAN receiving error.

Figure 13547-01

Event Code 868 and 869

Procedures listed apply to Event Codes 864 through 867.

ACCESS 8 and ACCESS 5 module CAN error.

No action taken.

Procedures listed apply to Event Codes 868 & 869. No action taken.

Crown 2006 PF15107-132 Rev. 5/09

TSP 6000 Series

M4.8-1960-172 03 Rev. 5/09

401

ELECTRICAL SYSTEM Event Codes - ACCESS 8 Event code 868: ACCESS 5 passive error. Event code 869: ACCESS 5 event control error. Step 1: Key truck ON. Check for +BV at ACCESS 5, CA403-1 (BNEG) and CA403-10 (+BV). If: +BV and event code persists. –

•

Then replace ACCESS 5.

If: 0 V. –

Then check wire #505 CA403-1 to negative buss bar and CA403-10 to FU8.

Step 2: Event code persists, key truck OFF. Using a DVOM check the resistance between ACCESS 8 CAN_H, CA504-3 and CAN_L, CA504-4. Resistance should be 60 Ω.

•

If: 0 Ω. –

• •

•

Event Code 870 and 871 ACCESS 8 and ACCESS 6 module CAN error.

–

Procedures listed apply to Event Codes 870 & 871.

Then replace ACCESS 8.

No action taken.

If: Infinity Ω, reconnect CA504 to ACCESS 8. Then disconnect CA402 from ACCESS 5. Check the resistance between module pins CA402-4 and CA402-5.

Event code 870: ACCESS 6 passive error. Event code 871: ACCESS 6 event control error.

If: 0 Ω.

Step 1: Key truck ON and check for +BV at ACCESS 6, CA601-2 (BNEG) and CA601-1 (+BV).

–

If: +BV and event code persists.

Then replace ACCESS 5.

–

If: 120 Ω. –

•

Figure 13690-01

If: 0 Ω.

–

•

Then a short exists between CAN_H and CAN_L. Disconnect CA504 from ACCESS 8 and check the resistance between module pins CA504-3 and CA504-4.

Then check the resistance between CA402-4 and CA402-5 on ACCESS 5 connector.

•

If: 0 V. –

If: 0 Ω. –

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 0 Ω. –

•

402

Then check wire #507 CA601-2 to NEG buss bar and CA403-1 to FU8.

Step 2: Event code persists, key truck OFF. Using a DVOM, check the resistance between ACCESS 8 CAN_H, CA504-3 and CAN_L, CA504-4. Resistance should be 60 Ω.

•

M4.8-1960-174 03 Rev. 5/09

Then replace ACCESS 6.

Then a short exists between CAN_H and CAN_L. Disconnect CA504 from ACCESS 8 and check the resistance between module pins CA504-3 and CA504-4.

If: 0 Ω.

TSP 6000 Series

Crown 2006 PF15107-133 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 –

•

If: Infinity Ω. Reconnect CA504 connector. –

•

Figure 13547-01

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other one is internal to ACCESS 5. Check the resistance between pins CA703-1 and CA703-12 on ACCESS 7.

If: 0 Ω. –

•

Then replace ACCESS 6.

If: Infinity Ω. –

•

Then disconnect CA601 from ACCESS 6 and check the resistance between module pins CA601-4 and CA601-5.

If: 0 Ω. –

•

Then replace ACCESS 8.

Then leave the meter leads connected to connector CA703 and disconnect CA402 from ACCESS 5.

Event Code 872 Through Event Code 874 ACCESS 8 and ACCESS 1 module CAN error. Procedures listed apply to Event Codes 872 through 874. No action taken. Event code 872: ACCESS 1 passive error. Event code 873: ACCESS 1 event control error.

If: 0 Ω.

Event code 874: ACCESS 1 CAN off line.

–

Step 1: Key truck ON and check for +BV at ACCESS 1, CA304-2 (BNEG) and CA304-3 (+BV).

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: +BV and event code persists.

If: 120 Ω. –

Then the resistor in ACCESS 5 is shorted. Replace ACCESS 5.

–

•

Then replace ACCESS 1.

If: 0 V. –

Then check the wiring between ACCESS 1, wire #512 CA304-2 to FU8 and CA403-1 to CA104-3, platform distribution panel.

Step 2: Event code persists, key truck OFF. Using a DVOM, check the resistance CAN_H, Ca504-3 and CAN_L, CA504-4 on ACCESS 8. Resistance should be 60 Ω.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Then replace ACCESS 8.

If: Infinity Ω. Reconnect CA504 to ACCESS 8. –

Then disconnect CA304 from ACCESS 1. Using a DVOM, check the resistance between module pins CA304-4 and CA304-5.

TSP 6000 Series

M4.8-1960-176 03 Rev. 5/09

Figure 13117-01 Crown 2006 PF15107-134 Rev. 5/09

Then a short exists between CAN_H and CAN_L. Disconnect CA504 from ACCESS 8 and check the resistance between module pins CA504-3 and CA504-4.

403

ELECTRICAL SYSTEM Event Codes - ACCESS 8 •

If: 0 Ω. –

•

If: Infinity Ω. –

•

Then leave the meter leads connected to CA703 and disconnect CA402 from ACCESS 5.

If: 0 Ω. –

•

Then there are two 60 Ω resistors. One is located in the wire harness close to CA701 and the other one is internal to ACCESS 5. Using a DVOM, check the resistance between CA703-1 and CA703-12 on ACCESS 7.

If: 0 Ω. –

•

Then replace ACCESS 1.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 120 Ω. –

Then resistor in ACCESS 5 is shorted. Replace ACCESS 5.

Figure 13547-01

Figure 13691-01

Event Code 875 Through Event Code 877 ACCESS 8 and ACCESS 4 module CAN error. Procedures listed apply to Event Codes 875 through 877. No action taken. Event code 875: ACCESS 4 passive error. M4.8-1960-177 03 Rev. 5/09

404

TSP 6000 Series

Crown 2006 PF15107-135 Rev. 5/09

ELECTRICAL SYSTEM Event Codes - ACCESS 8 Event code 876: ACCESS 4 event control error.

–

Event code 877: ACCESS 4 CAN off line.

Then the resistor in ACCESS 5 is shorted. Replace ACCESS 5.

Step 1: Key truck ON and check for +BV at ACCESS 4, CA314-2 (BNEG) and CA314-1 (+BV)

•

If: +BV and event code persists. –

•

Then replace ACCESS 4.

If: 0 V. –

Then check wire #2958 CA314-1 and wire #518 CA314-2 to platform distribution panel and FU7. Repair or replace as needed.

Figure 13547-01

Step 2: Event code persists, key truck OFF. Using a DVOM, check the resistance between CAN_H, CA504-3 and CAN_L, CA504-4 on ACCESS 8. Resistance should be 60 Ω.

•

If: 0 Ω. –

•

If: 0 Ω. –

•

Then leave the meter leads connect to CA703 and disconnect CA402 from ACCESS 5.

If: 0 Ω. –

•

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the one is internal to ACCESS 5. Check the resistance between CA703-1 and CA703-12 on ACCESS 7.

If: 0 Ω. –

•

Then replace ACCESS 4.

If: Infinity Ω. –

•

Then disconnect CA314 from ACCESS 4 and check the resistance between module pins CA314-3 and CA314-4.

If: 0 Ω. –

•

Then replace ACCESS 8.

If: Infinity Ω. Reconnect CA504. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA504 from ACCESS 8. Check the resistance between CA504-3 and CA504-4.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness. Figure 13699-01

If: 120 Ω. Crown 2006 PF15107-136 Rev. 5/09

TSP 6000 Series

M4.8-1960-179 03 Rev. 5/09

405

ELECTRICAL SYSTEM Event Codes - ACCESS 8 Event Code 878 Through Event Code 880

the resistance between CA703-1 and CA703-12 on ACCESS 7.

•

ACCESS 8 and ACCESS 7 module CAN error.

If: 0 Ω. –

Procedures listed apply to Event Codes 878 through 880.

•

No action taken. Event code 878: ACCESS 7 passive error.

•

Event code 880: ACCESS 7 CAN off line. Step 1: Key truck ON and check for +BV at ACCESS 7, CA703-8 (BNEG) and CA703-7 (+BV).

•

If: +BV and event code persists. –

•

If: 0 Ω. –

Event code 879: ACCESS 7 event control error.

Then the resistor in the wire harness is shorted. Replace the resistor or the wire harness.

If: 120 Ω. –

Then replace ACCESS 7.

Then replace ACCESS 5.

If: 0 Ω. –

•

Then leave the meter leads connected to CA703 and disconnect CA402 from ACCESS 5.

Then the resistor in ACCESS 5 is shorted. Replace ACCESS 5.

If: 0 V. –

Then check the wiring between ACCESS 7, CA703-1 and CA703-8 to platform distribution panel.

Step 2: Event code persists, key truck OFF. Using a DVOM, check the resistance between CAN_H, CA504-3 and CAN_L, CA504-4 on ACCESS 8. Resistance should be 60 Ω.

•

If: 0 Ω. –

•

Then disconnect CA703 from ACCESS 7 and check the resistance between module pins, CA703-1 and CA703-12.

If: 0 Ω. –

•

Then replace ACCESS 8.

If: Infinity Ω. Reconnect CA504. –

•

Figure 13641-01

If: 0 Ω. –

•

Then a short exists between CAN_H and CAN_L. Disconnect CA504 from ACCESS 8 and check the resistance between module pins, CA504-3 and CA504-4.

Then replace ACCESS 7.

If: Infinity Ω. –

Then there are two 60 Ω resistors. One is located in the wire harness close to CA703 and the other one is internal to ACCESS 5. Check

M4.8-1960-180 03 Rev. 5/09

406

TSP 6000 Series

Crown 2006 PF15107-137 Rev. 5/09

BRAKE SYSTEM

407

Notes:

408

BRAKE SYSTEM Brake

Brake

CAUTION

There are two sources of drive wheel braking, a 3-step, spring applied, electromagnetically released, disc brake on the drive motor armature shaft, and motor braking, typically called regenerative braking. If the operator is in a seated position, a brake request can be made by depressing one of the two brake pedals located along the front rail (BRS1, BRS2, BRS3, BRS4). If the operator is standing in the forward facing direction, a brake request can be made by removing either the left or right foot from an operator presence pedal (FPS1, FPS2, FPS3). When a brake request is made, the ACCESS 5 (SCM) microprocessor determines the amount of braking force to be applied. The braking force is split between the motor regenerative braking and the 3-step disc brake. The motor regenerative portion is made as large as practical in order to reduce wear on the 3-step disc brake. The forward and reverse brake force can be independently adjusted through the performance menu in ACCESS 1 (display module).

Brake Force Adjustment

The customer shall verify that the stopping distance in any part of the application doesn’t prevent the operator from performing a specific task safely, or result in braking characteristics that are significantly different from other similar vehicles being used in the facility. An alternative is for the customer to train the operator to reduce travel speed and/or allow for longer stopping distances. 4. If brake force adjustments are necessary, verify the settings in steps A and B before proceeding to step C. –

Step A: Using the display, verify that the features F13 (truck weight) and F14 (maximum load) are correct. Information for these settings can be found on the trucks data and capacity plates.

–

Step B: Verify that the drive brake torque gap and air gap settings are correct (refer to following sections).

–

Step C: To adjust braking force in the forks first (FF) or power unit first (PUF) direction, adjust performance settings P6.1 Braking FF or P6.2 Braking PUF. Adjusting to a higher number will increase braking force (reduce stopping distance). Adjusting to a lower number will decrease braking force (increase stopping distance or reduce tire slide).

1. Braking force should be checked under the following conditions: –

forks lowered

–

on a floor surface typical of the application

–

both forward and reverse travel directions

–

with and without a load

Torque Gap Adjustment

2. The brake force should be adjusted to produce the shortest possible stopping distance without causing the braking wheel to slide or the load to become unstable. A brake setting of 6 or 7 is typical for a properly functioning brake system on smooth dry concrete floors. For reference, a typical stopping distance when traveling at the maximum nonguided speed of 8.8 km/h (5.5 mph) in the forks first direction with no load is 2.5 to 3.0 meters (8 to 10 ft).

The torque gap, referred to on this truck, is the distance between the torque adjuster plate and the electromagnet. Refer to Figure 20792. The torque plate is factory preset and no adjustment is required, however, through routine maintenance it may be necessary to replace components and the gap may need to be reset to factory specifications. The torque gap will vary with each truck based on its' maximum load and truck weight (see chart 1).

3. If the floor conditions are such that tire slide occurs or a more/less aggressive stop is desired, the braking force can be increased or decreased with a corresponding increase or decrease in stopping distance.

NOTE

Crown 2005 PF15091-1 Rev. 1/09

Refer to the truck's capacity and data plates for maximum load and truck weight as equipped with maximum battery weight.

TSP 6000 Series

M5.0-1960-001 03 Rev. 1/09

409

BRAKE SYSTEM Brake CHART 1 – TORQUE GAP CHART 1 – TORQUE GAP Torque Gap GVW (capacity load and max. battery) mm

0.00

0.00 greater than 9934 greater than 21900

0.51

0.02

9480 - 9933

20900 - 21899

1.02

0.04

9004 - 9479

19850 - 20899

1.52

0.06

8550 - 9003

18850 - 19849

2.03

0.08

8074 - 8549

17800 - 18849

2.54

0.10

7620 - 8073

16800 - 17799

3.05

0.12

7167 - 7619

15800 - 16799

3.56

0.14

less than 7167

less than 15800

Figure 20792 1

Torque Adjuster Plate

7/8 inch Hex Nut

Adjuster Disk

Rotor

Electromagnet

Brake Pads

Air Gap

Outer Armature

1-1/8 inch Hex Nut

Torque Adjuster Gap

Motor Shaft

Drive Motor

M5.0-1960-002 03 Rev. 1/09

410

TSP 6000 Series

Crown 2005 PF15091-2 Rev. 1/09

BRAKE SYSTEM Brake Air Gap Adjustment

2. Open power unit doors to access brake assembly. 3. Using low pressure air, remove any dirt between armatures and magnet body.

The air gap, referred to on this truck, is the distance between the brake armature and the electromagnet body with brakes applied. Refer to Figure 20792. As the brake pads and rotor wear normally, the air gap will increase and should be readjusted, or parts checked and replaced, when it exceeds 1.0 mm (0.040 in).

4. Using a 7/8 inch open end wrench, loosen the top nut. 5. Using a 1-1/8 inch open end wrench, turn the 1-1/ 8 inch hex nut down until the air gap is 0.25 mm (0.010 in) at its tightest location. One complete turn of the nut will change the gap 1.4 mm (0.056 in) or 1/6 (60 degrees) turn will change gap 0.235 mm (0.009 in).

NOTE If the air gap measures more than 1.0 mm (0.040 in), the brake may not release properly. If the brake pad thickness is less than 2.8 mm (0.110 in), the brake pads and rotor should be replaced.

6. Torque the 7/8 inch hex nut to 122 Nm (90 ft lb). 7. Remove chocks, connect the battery, and check operation.

1. Lower forks completely, chock load wheels, and disconnect the battery.

Figure 20792 1

Torque Adjuster Plate

Adjuster Disk

Rotor

Electromagnet

Brake Pads

Air Gap

Outer Armature

1-1/8 in Hex Nut

Torque Adjuster Gap

Motor Shaft

Drive Motor

Crown 2005 PF15091-3 Rev. 1/09

7/8 in Hex Nut

TSP 6000 Series

M5.0-1960-003 03 Rev. 1/09

411

BRAKE SYSTEM Brake Rotor and Brake Pad Replacement Tools are available from Crown to permit replacement of the pads on the brake pad assembly. When used with a press, these tools allow the correct positioning of the pads and correct setting of the rivets. A press is required to insure the rivets provide the compression strength needed to keep brake pads stationary.

2. Apply a light coat of multipurpose grease (063002-024) to the motor end cap threads and on top of the torque adjuster plate (2). 3. Place adjuster disk (3) on torque adjuster plate (2). 4. Position the magnet body (4) on the motor (1) so the coil wires (7) are positioned as shown in Figure 21232. Apply blue thread locking adhesive (061004-026) to the three M8 x 40 mm hex socket head cap screws (6) and secure magnet to motor with screws. 5. Assemble springs (5), inner and outer armatures (8 & 9) to magnet body (4). 6. Apply a light coat of multipurpose grease (063002-024) to entire bottom of brake pad plate assembly (11). Be careful not to contaminate brake pads with grease. Install on top of armatures. 7. Install compression spring (10) over armature shaft.

Figure 21231 1

119343 Riveter Base

114518 Riveter

To disassemble rotor and brake pad assembly: 1. Lower forks completely, chock load wheels, and disconnect the battery. 2. Open power unit doors and disconnect brake connector from CA407. 3. Remove retaining ring, washers, and two hex nuts. 4. Remove rotor and brake pad assembly. 5. Follow Brake Assembly procedure when reassembling the brake.

8. Slip rotor (12) on motor shaft, hub first. Thread 1-1/8 inch hex nut (13) onto motor shaft. Tighten the nut until the rotor moves down and almost touches the brake pads. Proper air gap adjustment will be made later. 9. Thread the 7/8 inch hex nut (14) onto motor shaft. Add flatwasher(s) (15) and place retaining ring (16) on motor shaft. 10. Set torque adjuster gap to its original factory setting. See Torque Gap Adjustment procedures. 11. Connect wire harness to brake assembly. 12. Adjust air gap. See Air Gap Adjustment procedures. 13. Check brake operation and stopping distance. See Brake Force Adjustment procedures.

Brake Assembly Refer to Figure 21232. Before assembling brake, inspect all components for wear, grooves, nicks or other damage. If any abnormal wear or damage appears that may affect brake operation, replace with new parts. Assemble brake as follows: 1. Assemble torque adjuster plate (2) by threading it onto the motor end cap as far as possible to reduce spring force.

M5.0-1960-004 03 Rev. 1/09

412

TSP 6000 Series

Crown 2005 PF15091-4 Rev. 1/09

BRAKE SYSTEM Brake

Figure 21232

Crown 2005 PF15091-5 Rev. 1/09

TSP 6000 Series

M5.0-1960-005 03 Rev. 1/09

413

BRAKE SYSTEM Brake CHART 2 - TROUBLESHOOTING Problem

Probable Cause

Remedy

Brakes will not release

Air gap more than 1.0 mm (0.040 in)

Adjust

Open circuit in brake circuitry or wiring

Check floorboard switches and all associated wiring

Armatures movement restricted by dirt, for- Clean with low pressure air eign material Brakes drag

Air gap less than 0.25 mm (0.010 in)

Adjust

Brake pad mounting plate or rotor distorted Replace Armatures movement restricted by dirt, for- Clean with low pressure air eign material Brakes grab

Incorrect stopping distance adjustment

Adjust (See Brake Force Adjustment Section)

Brake pad mounting plates or rotor distorted Replace Stopping distance too long Incorrect stopping distance adjustment Brake pads loose or soiled with grease

Adjust (See Brake Force Adjustment Section) Replace

Abnormal noise and chatter Brake pad mounting plate or rotor distorted Replace when brakes applied Brake pads worn out, loose, soiled with Replace grease, foreign material embedded Abnormal braking force for Rotor thin, cracked or spline worn lift height or brakes applied WIRE GUIDE TRUCKS: Guide wire lost without request power or truck off guide wire Open circuit in brake circuitry or wiring

M5.0-1960-006 03 Rev. 1/09

414

TSP 6000 Series

Replace Troubleshoot wire guidance system Check all switches and associated wiring

Crown 2005 PF15091-6 Rev. 1/09

STEERING

415

Notes:

416

STEERING Steering Feedback

Steering Feedback Replacing Steering Feedback Assembly Encoder Refer to Figure 21246. 1. Lower forks completely, chock load wheels, and disconnect the battery. 2. Remove rear door on power unit to obtain access to steering feedback assembly. 3. Remove steering feedback assembly cover (1). 4. Disconnect encoder (3). 5. Loosen set screw (18) in gear assembly (17) shaft. Then remove screws (6) and cleats (5) that secure encoder to retainer (4) and remove encoder (3). 6. Install new encoder and secure to retainer (4) using screws (6) and cleats (5) previously removed. 7. Tighten set screw (18) to secure encoder shaft to gear assembly (17) shaft. Make certain set screw is tightened on flat part of encoder shaft. 8. Connect encoder. 9. Connect battery and remove load wheel chocks. 10. At this time, the steering encoder alignment must beset. Follow the procedure outlined under Steering Encoder Alignment. Drive Unit Mounting Plate

CAUTION The steering indicator will not represent the proper steer angle. The steering feedback encoder must be set to ensure the steered wheel is set to straight ahead position.

Figure 21246

Crown 2005 PF15094-1 Rev. 1/09

TSP 6000 Series

M6.0-1960-001 01 Rev. 1/09

417

STEERING Steering Feedback Replacing Steering Feedback Assembly Gears (Ref. Figure 21246) 1. Lower forks completely, chock load wheels, and disconnect the battery. 2. Remove rear door on power unit to obtain access to steering feedback assembly. 3. Remove steering feedback assembly cover (1). 4. Disconnect encoder (3). 5. Disconnect spring (7) from retainer (4). Then loosen setscrew (18) in gear assembly (17) shaft and remove encoder and retainer (3 & 4) as one assembly.

NOTE Before disassembling the remaining components, note the location and quantity of flatwashers (10, 11, 13 & 15) and also the orientation of bearings (12) for reassembly purposes. 6. While supporting gears from below, remove retainer ring (9), flatwashers (10 & 11), and bearing (12). Then remove gears and remaining components from drive unit mounting plate. 7. Disassemble gears and associated components. 8. Inspect bearings (12). Replace if worn or damaged.

Drive Unit Mounting Plate

9. Inspect gear (14) and gear assembly (17). Replace if worn or damaged. 10. Place flatwasher (15) and first bearing (12) on gear assembly (17) shaft. 11. Place one end of spring (16) into the small hole on the gear assembly (innermost to the shaft). Then install gear (14) on gear assembly (17) shaft aligning the other end of the spring (16) with the small hole in gear (14). 12. Install flatwashers (13) and second bearing (12) on gear assembly (17) shaft.

Figure 21246

M6.0-1960-002 01 Rev. 1/09

418

TSP 6000 Series

Crown 2005 PF15094-2 Rev. 1/09

STEERING Steering Feedback 13. Install third bearing (12) on top of drive unit mounting plate as shown in Figure 21246. 14. Turn top gear (14) until the small outermost slots on both gears are aligned (approximately 4 to 5 teeth) and place a 3 mm (0.125 in) diameter pin or drill bit into the slots (from bottom side) to keep the gears aligned. 15. Slide gear assembly (17) shaft up through drive unit mounting plate. Position gears so threaded hole in gear assembly (17) shaft is facing rear of truck to allow for easy access. 16. Once gears are meshed with drive unit gears, install flatwashers (10 & 11) to set the height. The desired position of the gear assembly is such that it's centered on the drive unit gear or just slightly above center. 17. Install retaining ring (9) to secure gear assembly (17) to drive unit mounting plate. 18. Install encoder (with retainer attached) and insert encoder shaft into gear assembly (17) shaft. 19. Connect spring (7) to retainer (4). Then tighten setscrew (18) to secure encoder shaft to gear assembly (17) shaft. Make certain set screw is tightened on flat part of encoder shaft. 20. Connect encoder. 21. Connect battery and remove load wheel chocks. 22. At this time, the steering encoder alignment must be set. Follow the procedure outlined under Steering Encoder Alignment.

CAUTION The steering indicator will not represent the proper steer angle. The steering feedback encoder must be set to ensure the steered wheel is set to straight ahead position. Steering Encoder Alignment 1. Power the truck up in Field Service Mode by pressing and holding the UP button on ACCESS 1 during key up. 2. After ACCESS 1 displays Service Access Level, enter the service access code one digit at a time by using the UP or DOWN button and then the SELECT button. Scroll to Calibration and press the SELECT button.

Crown 2005 PF15094-3 Rev. 1/09

3. Before selecting C4 Steer Encoder, rotate the steer wheel to the straight-ahead position using the steering tiller. The alignment hole in the steering ring gear should be near the mounting plate hole. Since the steer encoder has not been aligned, the steer wheel position indicator on the display may not be accurate. Therefore, one should visually view the steer wheel position from the rear of the truck. 4. Scroll to C4 Steer Encoder and press the SELECT button. Manual steering and traction are now disabled. 5. Using a floor jack, lift power unit until steer wheel is off the floor. Then, turning the steer wheel manually, align and place a 12.7 mm (0.50 in) diameter alignment pin through the two holes. A wooden dowel is preferred; however, a steel pin (i.e., a 3/8 inch drive extension bar) will work if this procedure is strictly followed. 6. Loosen the two screws that secure the steering feed-back encoder so that the encoder body can be rotated. 7. If the encoder has not seen index since the truck was powered up, rotate the encoder to find the index. ACCESS 1 will display Rotate ECR to Index until the encoder sees first index. 8. Rotate encoder until index is at straight-ahead wheel position. The continuous alarm is active when the encoder is at index (within ± 4 counts of index). Also, the number of counts from index is shown on ACCESS 1. With the steering feedback encoder at index, tighten the two encoder screws. Make sure the flat sides of both cleats are facing outward from the encoder to ensure maximum engagement. After tightening the two screws, the continuous alarm should still be active. 9. Before selecting Escape, remove alignment pin, lower truck, and remove the floor jack. 10. Select Escape. ACCESS 1 will display C4 Steer Encoder. Power down and back up and rotate the steer wheel through the straight-ahead position to find first index. With only the green LED lit on steer wheel position indicator, visually verify that the steer wheel is at the straight-ahead position. 11. Install steering feedback assembly cover and rear door on power unit.

TSP 6000 Series

M6.0-1960-003 01 Rev. 1/09

419

STEERING Steering Motor

Steering Motor

8. Install rear door on power unit, remove load wheel chocks, and connect the battery.

Steering Motor Brushes

Replacing Steering Motor

It is recommended that all steering motor brushes be replaced when any of the brushes reach the minimum allowable length of 6.4 mm (0.25 in). In addition, it is also recommended that the springs be replaced when the brushes are replaced.

Replacing Steering Motor Brushes 1. Disconnect battery and chock load wheels.

1. Disconnect battery and chock load wheels. 2. Remove rear door on power unit to obtain access to steering motor. 3. Note the position of steering motor terminal leads (2) for future reference during installation (refer to Figure 21248). Then disconnect leads from steering motor.

2. Remove rear door on power unit to obtain access to steering motor. Remove brush inspection cover (1) to obtain access to brushes (2) and springs (3). Refer to Figure 21247.

PowerUnit (RH Side)

Figure 21247

3. Remove and discard brushes and springs. 4. Install new brushes and springs. 5. Remove dust from motor using low pressure compressed air. Protect eyes and face when using low pressure compressed air. 6. Rotate armature and check for irregularities or other damage. Make certain all brushes exert uniform pressure on armature. Replace armature if necessary.

NOTE An evenly distributed carbon layer on the brush contact surfaces is considered normal.

Figure 21248

4. Remove the four M8 Locknuts (3) used to secure the steering motor and gearbox to the drive unit mounting plate (5). Then remove steering motor and gearbox. 5. Remove isolator (6) from gearbox to obtain access to steering motor mounting screws (8). Refer to Figure 21249.

7. Install brush inspection cover on motor and tighten screw securely.

M6.0-1960-100 01 Rev. 1/09

420

TSP 6000 Series

Crown 2005 PF15095-1 Rev. 1/09

STEERING Steering Motor blue thread locking adhesive Grade 242 (061004026) to threads of screws, install screws, and torque them to a value of 5.4 Nm (4 ft lb). 12. Install isolator (6) (previously removed in Step 5) on gearbox. 13. Apply molydisulfide grease (063002-022) to steering pinion and steer gear. Then install steering motor and gearbox on mounting bolts in drive unit mounting plate while making certain motor terminal leads are positioned as noted in Step 3. 14. Secure steering motor and gearbox to drive unit mounting plate using the four M8 Locknuts previously removed in Step 4. Torque locknuts to a value of 23 Nm (17 ft lb). 15. Attach leads to appropriate motor terminals and torque nuts to 4.5 Nm (40 in lb). 16. lnstall rear door on power unit, remove load wheel chocks, and connect the battery.

Cross Section View of Gearbox

Figure 21249

6. Remove the four steering motor mounting screws used to secure the steering motor (1) to the gearbox (4) but do not remove the motor from the gearbox (see NOTE below). Then block steering motor and gearbox in an upright position.

NOTE With the motor removed, the internal components of gearbox are not restrained and could fall out if gearbox is overturned. 7. Remove steering motor from gearbox. 8. Visually inspect gearbox components for signs of wear or damage. Replace parts as necessary. 9. Make certain internal gearbox components are properly lubricated. Add molydisulfide grease (063002-022) as necessary to properly lubricate components. 10. Install new motor onto gearbox. After meshing gears, align mounting holes as the motor is seated into gearbox. 11. Secure motor to gearbox using the four steering motor mounting screws that were previously removed in Step 6. Clean threads of screws, apply

Crown 2005 PF15095-2 Rev. 1/09

TSP 6000 Series

M6.0-1960-100 01 Rev. 1/09

421

STEERING Steering Gearbox

Steering Gearbox

4. Remove the four M8 Locknuts (3) used to secure the steering motor (1) and gearbox (4) to the drive unit mounting plate (5). Then remove steering motor and gearbox.

Replacing Steering Gearbox 1. Disconnect battery and chock load wheels. 2. Remove rear door on power unit to access steering motor.

5. Remove isolator (6) from gearbox to obtain access to steering motor mounting screws (8). Refer to Figure 21249.

3. Note the position of steering motor terminal leads (2) for future reference during installation (refer to Figure 21248). Then disconnect leads from steering motor (1).

Power Unit (RH Side)

Cross Section View of Gearbox

Figure 21249

6. Remove the four steering motor mounting screws used to secure the steering motor (1) to the gearbox (4) and remove the motor from the gearbox.

Figure 21248

7. Install new steering gearbox. Begin by blocking the gearbox (4) in an upright position and removing nuts (9) from steering motor mounting screws (8). Then remove shipping cover (10) (refer to Figure 21252).

NOTE With the shipping cover removed, the internal components of gearbox are not restrained and could fall out if gearbox is overturned.

M6.0-1960-200 01 Rev. 1/09

422

TSP 6000 Series

Crown 2005 PF15113-1 Rev. 1/09

STEERING Steering Gearbox

Figure 21252

8. Make certain internal gearbox components are properly lubricated. Add molydisulfide grease (063002-022) as necessary to properly lubricate components. 9. Install steering motor onto gearbox. After meshing gears, align mounting holes as the motor is seated into gearbox. 10. Secure motor to gearbox using the four steering motor mounting screws that were previously removed in step 6. Clean threads of screws, apply blue thread locking adhesive Grade 242 (061004026) to threads of screws, install screws, and torque them to a value of 5.4 Nm (4 ft lb). 11. Install isolator (previously removed in Step 5) on gearbox. Refer to Figure 21249. 12. Apply molydisulfide grease (063002-022) to steering pinion and steer gear. Then install steering motor and gearbox on mounting bolts in drive unit mounting plate while making certain motor terminal leads are positioned as noted in Step 3. 13. Secure steering motor and gearbox to drive unit mounting plate using the four M8 Locknuts previously removed in Step 4. Torque locknuts to a value of 23 Nm (17 ft lb). 14. Attach leads to appropriate motor terminals and torque nuts to 4.5 Nm (40 in lb). 15. Install rear door on power unit, remove load wheel chocks, and connect the battery.

Crown 2005 PF15113-2 Rev. 1/09

TSP 6000 Series

M6.0-1960-200 01 Rev. 1/09

423

STEERING Steering Gearbox

Notes:

M6.0-1960-200 01 Rev. 1/09

424

TSP 6000 Series

LIFTING MECHANISM

425

Notes:

426

LIFTING MECHANISM Mast

Mast Masts are constructed of hot rolled carbon steel Ibeams continuously welded to a flat and formed plate. They telescope on alloy steel column and carriage rollers. Elevated load sway due to mast twisting, plus forward and side bowing are minimized through the use of closed cross section construction. The lift cylinders, hydraulic hoses, electrical cables and lift chains are protected within the mast and yet are readily accessible.

TN (Telescopic No Free Lift) Mast The TN mast is a two stage mast assembly which incorporates a single lift cylinder assembly. When the main raise function of the truck is used the mast begins staging and the platform raises simultaneously to the full lifting height of the truck. The main mast chains are attached to the operator compartment and are routed over a chain roller in the tip-out assembly at the top of the mast. The chains are anchored to the top of the mainframe.

TF (Telescopic Full Free Lift) Mast The TF mast is a two stage mast assembly which incorporates a shorter, twin primary lift cylinder assembly and a longer single cylinder assembly. The operator compartment will raise to the top of the second stage mast through the extension of the two shorter rams in the primary lift cylinder assembly. After these cylinders are fully extended, the remaining cylinder ram will push the second stage from the first stage until the maximum lift height is attained. The main mast chains are attached to the operator compartment and are routed over a chain roller at the top of the single lift cylinder, through the yoke assembly of the primary lift cylinder, and attached to a chain anchor at top of the second stage tip out assembly.

TT (Triple Telescopic Full Free Lift) Mast The TT is a three stage mast assembly providing a high lift height while maintaining a low collapsed height. The TT incorporates two primary lift and a secondary cylinder assembly. The operator platform will raise to the top of the mast through the extension of the two shorter rams in the primary lift cylinders. As the platform nears the top of the mast it contacts a pair of stops. At this time the secondary lift cylinder begins to extend and the second and third stage masts begin to extend until maximum lift height is attained. The primary lift cylinders are attached to the third stage mast. A pair of lift chains are attached at the top of the primary lift cylinders and routed through two yokes, one at the top of each primary lift cylinder, and are attached to the bottom of the platform. As the primary lift cylinders extend the chains lift the platform compartment. The secondary cylinder is attached to the mainframe, or first stage mast and to the top of the second stage mast. A pair of lifting chains are attached at the top of the mainframe, routed through a set of rollers at the top of the second stage mast, and attached to the bottom of the third stage mast. As the secondary lift cylinder lifts the second stage mast the chains lift the third stage mast.

NOTE This section pertains only to second or third stage mast removal and column and side thrust roller adjustments. Maintenance information pertaining to cylinder repair and removal, 2nd stage mast blocking, etc. is found in the Control of Hazardous Energy section and in the Cylinders section of this manual.

New Truck Assembly Procedures Depending upon the lift height, shipping destination, or special shipping arrangements of your truck, the truck may arrive fully assembled or possibly in two or more sections (i.e., power unit, mainframe, platform, load handler or power unit, mainframe, platform, load handler). If your truck requires only that the load handler be installed, refer to platform maintenance section for installation procedures. However, if your truck requires assembly of the power unit to the mainframe and platform, refer to the procedure outlined below.

Crown 2005 PF15129-1 Rev. 12/08

TSP 6000 Series

427

LIFTING MECHANISM Mast To Assemble Power Unit, Mainframe and Platform and Load Handler: WARNING Lifting equipment with insufficient capacity and/or size may break or become unstable resulting in an unsafe condition. • Make certain the lifting equipment is of sufficient capacity or size to safely handle the mainframe and platform assembly. 1. Attach lifting equipment to the shipping bracket at the top and the bottom of the mainframe. Make certain the lifting equipment is of sufficient capacity or size to safely handle the mainframe and platform assembly. The weight of the mainframe and platform for a TF or TN assembly is approximately 3630 kg (8000 lb), and the TT mainframe and platform assembly weights approximately 4082 kg (9000 lb). Extreme care must be exercised during this procedure. 2. Carefully raise the mainframe and platform assembly until the mast is in a vertical position. Then place blocks beneath mainframe and chock load wheels as shown in Figure 13036-01. Make certain to secure the assembly in a manner that will prevent the mast from going beyond a vertical position.

3. Remove lifting equipment from mainframe and platform assembly. 4. Position power unit in proper alignment with mainframe and platform assembly. Place blocks beneath power unit and chock drive wheel. 5. Install mounting bolts, two at top, 060099-007, and six at bottom, 060131-005, through power unit with bolt heads pointing towards power unit. Install shims, 060131-006 thru -008, between power unit and mainframe. Make certain shims are installed in correct location. Then install flatwashers 060131-005, and hex nuts 060059-035, on mounting bolts. Refer to Figure 20932.

NOTE The correct combination of shims is determined at the factory on a surface plate, for each truck, to achieve the correct mast back tilt. Use these shims as supplied with each truck for assembly. For most trucks this will consist of one 6 mm (0.25 in) thick shim being used on each side between the mast mainframe and the top of the power unit.

Figure 20932

Figure 13036-01 1 2

Block Both Sides

060131-007, 3 mm (0.12 in) Thick

Load Wheel Chocks Both Sides

060131-006, 6 mm (0.25 in) Thick

060131-008, 1.8 mm (0.07 in) Thick

TSP 6000 Series

428

Crown 2005 PF15129-2 Rev. 12/08

LIFTING MECHANISM Mast 6. Refer to Figure 20933. Using a torque wrench, first tighten the mounting bolts to 305 Nm (225 ft lb) in the sequence shown. Next tighten all 8 bolts to 435 Nm (320 ft lb) in the same sequence, then verify the 435 Nm (320 ft lb) torque on each bolt. Torque Value and Sequence

Figure 20933

Torque bolts in the sequence shown in the following steps: –

Step 1: 305 Nm (225 ft lb)

–

Step 2: 435 Nm (320 ft lb)

–

Step 3: Verify torque of 435 Nm (320 ft lb)

7. Connect electrical connections from power unit to mainframe. Refer to wiring diagrams in the Service and Parts Manual. 8. Connect manual lowering valve cable. 9. Remove shipping bracket from top of mast. Store bracket and associated hardware for future use. 10. Remove non-vented cap from the reservoir and replace it with the vented filler and breather cap that was shipped (loose) with the truck. Store nonvented cap for future use. 11. Install any covers that were shipped loose with the truck. 12. Install load handler. Refer to the Platform maintenance section for installation procedures.

Crown 2005 PF15129-3 Rev. 12/08

TSP 6000 Series

429

LIFTING MECHANISM Mast

Figure 13038-01

M7.0-1960-004

430

TSP 6000 Series

Crown 2005 PF15129-4 Rev. 12/08

LIFTING MECHANISM Mast Second Stage Mast Removal TF and TN Should it become necessary to remove the second stage mast, the procedure to follow is dependent upon the amount of available overhead clearance. If sufficient clearance is available, the truck can remain intact during removal of the mast. However, if sufficient clearance is not available, the load handler and platform must be removed, the mainframe and power unit will have to be separated, and the mainframe must be laid down. Procedures are provided for both cases. Follow the applicable procedure when removing the second stage mast from your truck.

Removing Second Stage Mast TF and TN Figure 13039-01

(Without Sufficient Overhead Clearance) 1. Move truck to a service area with a level floor that will allow the second stage mast to be extended completely when laid down. 2. Completely lower mast, disconnect battery and Lockout/Tagout truck as described in the Control of Hazardous Energy section. Open manual lowering valve to relieve hydraulic line pressure.

Block Both Sides

Load Wheels Chocked

9. Replace the vented filler and breather cap on the reservoir with the non-vented cap that was originally shipped with the truck. Make certain cap fits securely. Or, if the non-vented cap is not available, drain the hydraulic reservoir.

3. Remove load handler assembly. Refer to Platform maintenance section for load handler removal procedure.

10. Disconnect any electrical connections that prohibit the separation of the power unit and the mainframe. Record wire termination points for reference at reassembly.

4. Remove platform from mainframe. Refer to Platform maintenance section for platform removal procedure.

11. Remove cable that goes to the height sensor cable break limit switch, if equipped.

5. Remove lift cylinders from mainframe. Refer to Cylinder maintenance section for cylinder removal procedure. 6. Remove power unit doors and covers. 7. Remove battery. 8. Block the mainframe in such a manner that it will be self-supporting when the power unit is unbolted. Then block the power unit in the same manner so that it will not drop to the floor when removed from the mainframe. Refer to Figure 13039-01.

Crown 2005 PF15129-5 Rev. 12/08

12. Remove main lift motor cables from motor. Note cable connections for reference at reassembly. 13. On trucks equipped with wire guidance, remove the cable from the sensor bar at the front of the mainframe. Note termination points for future reference. 14. Secure any and all cables that have been disconnected to the mainframe to prevent possible damage when removing the second stage mast. 15. Remove the eight bolts used to secure the power unit to the mainframe. Refer to Figure 20932. When removing the bolts, record the number and position of all flatwashers and mounting hardware. This information will be used when the power unit is bolted to the mainframe at reassembly.

TSP 6000 Series

M7.0-1960-004

431

LIFTING MECHANISM Mast 16. Visually check the power unit to confirm that all cables connecting the power unit to the mainframe have been disconnected. Then carefully separate power unit and mainframe. 17. Install the shipping bracket, originally shipped with truck, on top of the second stage mast and secure it to the mainframe using the mounting hardware that was furnished with the bracket. Refer to Figure 13040-01.

19. Carefully lift the mainframe. As the mast assembly becomes horizontal, block as shown in Figure 13041-01. Disconnect lifting equipment from shipping bracket at top of second stage mast and remove bracket.

Load Wheel Chocks (Both Sides)

Figure 13041-01

20. Remove the two covers from the second stage mast that allow access to the poly stops mounted to the mainframe. Then remove stops. Refer to Figure 13042-01. Figure 13040-01 1

Bracket 109431

Screw (2) 060023-022, Lockwasher (2) 060005-023, Flatwasher (2) 060030-054

Roll Pin (2) 060000-022

Pin 092832

WARNING Lifting equipment with insufficient capacity and size may break or become unstable resulting in an unsafe condition. • Make certain the lifting equipment is of sufficient capacity and size to safely handle the mainframe. 18. Attach lifting equipment to the shipping bracket and also to the base of the mainframe. Make certain the lifting equipment is of sufficient capacity and size to safely handle the mainframe. Extreme care must be exercised during this procedure.

WARNING Load wheels must remain securely chocked throughout this procedure.

M7.0-1960-004

432

TSP 6000 Series

Crown 2005 PF15129-6 Rev. 12/08

LIFTING MECHANISM Mast

Figure 13042-01 1

Poly Stop Assemblies

Covers

rangement is recommended. Refer to Figure 13043-01.

WARNING Make certain that the lifting equipment is attached to the second stage mast in such a manner that will prevent the bottom of the mast from dropping when it clears the mainframe I-beam area (extended completely). Failure to do so could result in serious injury and/or damage to truck components. 21. Attach lifting equipment to second stage mast. Make certain lifting equipment is attached in such a manner that will prevent the bottom of the mast from dropping when it clears the mainframe I-beam area (extended completely) and also prevent shifting of the mast and/or mainframe. The use of a spreader bar or other weight-balancing type ar-

Crown 2005 PF15129-7 Rev. 12/08

TSP 6000 Series

M7.0-1960-008

433

LIFTING MECHANISM Mast .

Figure 13043-01 1

Load Wheel Chocks, Both Sides

Attach Sling, Chain, etc.

To Lifting Device

22. Raise the mast assembly just enough so that the second stage is not in contact with the support. Then carefully move the second stage mast toward the top of the mainframe. As the mainframe and second stage mast are near full extension, reposition the support under the mainframe. Refer to Figure 13044-01. If necessary, place supports beneath mast, lower mast, and reposition lifting equipment to ensure proper weight distribution.

M7.0-1960-008

434

TSP 6000 Series

Crown 2005 PF15129-8 Rev. 12/08

LIFTING MECHANISM Mast

Figure 13044-01 1

Load Wheel Chocks, Both Sides

Attach Sling, Chains, etc.

To Lifting Device

WARNING

23. Continue moving the second stage mast toward the top of the mainframe. Guide any mast chains, hydraulic lines, and electrical cables from mast assembly if necessary. Record location of parts attached to the second stage and mainframe for reference at reassembly.

Lifting equipment with insufficient capacity and size may break or become unstable resulting in an unsafe condition. • Make certain the lifting equipment is of sufficient capacity and/or size to safely handle the second stage mast.

24. Move the second stage mast aside, either to the floor or onto supports while performing repair to mainframe or second stage mast.

4. Attach lifting equipment to second stage mast. Make certain the lifting equipment is of sufficient capacity and size to safely handle the second stage mast.

Removing Second Stage Mast TF and TN

5. Carefully remove the second stage mast from the mainframe and move it aside either to the floor or onto supports while performing repair to mainframe or second stage mast.

(With Sufficient Overhead Clearance) 1. Completely lower mast, disconnect battery, chock load wheels and drive tire, and Lockout/Tagout truck as described in the Control of Hazardous Energy section. Open manual lowering valve to relieve hydraulic line pressure.

Removing Second and Third Stages from TT Mast Assembly 1. Move truck to a service area with a level floor that will allow the TT mast to be extended completely when laid down.

2. Remove lift cylinders from mainframe. Refer to Cylinder maintenance section for cylinder removal procedures.

2. Completely lower mast, disconnect battery and Lockout/Tagout truck as described in the Control of Hazardous Energy section.

3. Remove the two covers from the second stage mast that allow access to the poly stops mounted to the mainframe. Then remove stops. See Figure 13042-01.

3. Remove hydraulic line pressure by opening the manual lowering valve as described in the Control of Hazardous Energy section before proceeding.

Crown 2005 PF15129-9 Rev. 12/08

TSP 6000 Series

M7.0-1960-010

435

LIFTING MECHANISM Mast 4. Remove load handler assembly. Refer to the Platform maintenance section for load handler removal procedure.

7. Remove free lift cylinders from third stage mast. Refer to the Cylinder maintenance section for cylinder removal procedures.

5. Remove platform from mast assembly. Refer to the Platform maintenance section for platform removal procedure.

8. Remove power unit doors and covers.

6. Loosen nuts on chain anchors at bottom of third stage mast until the bottom nuts contact the cotter pin. Do not remove the chain anchors, just loosen them to relieve chain tension from springs at top of mainframe. Refer to Figure 20985.

9. Remove battery. 10. Block the mainframe so that it will be self-supporting when the power unit is unbolted. Then block the power unit so that it will not drop to the floor when removed from the mainframe. Refer to Figure 13039-01.

Figure 13039-01 Figure 20985 1

Bottom of Third Stage Mast

Chain Anchor Nuts

Cotter Pin

Block Both Sides

Load Wheels Chocked

11. Replace the vented filler and breather cap on the reservoir with the non-vented cap that was originally shipped with the truck. Make certain cap fits securely. If the non-vented cap is not available, drain the hydraulic reservoir. 12. Disconnect any electrical connections between the power unit and the mainframe. Record wire termination points for reference at assembly. 13. Remove main lift pump motor cables from the motor. Note cable connection location for reference at assembly. 14. For trucks with wire guidance, remove the cable from the sensor bar at the front of the mainframe. Note termination points for future reference. 15. Secure all cables that have been disconnected from the mainframe to prevent possible damage when removing the second and third stage mast.

M7.0-1960-010

436

TSP 6000 Series

Crown 2005 PF15129-10 Rev. 12/08

LIFTING MECHANISM Mast 16. Remove eight bolts used to secure the power unit to the mainframe. When removing the bolts, record the number and position of all shims and mounting hardware. This information will be used when the power unit is bolted back on to the mainframe. Refer to Figure 20932.

18. Install the shipping bracket, originally shipped on truck, on top of the TT mast assembly and secure it to the mainframe using the mounting hardware that was furnished with the bracket. Refer to Figure 20986.

Figure 20986 Figure 20932

143043 Shipping Bracket TT

092832 Pin

060131-007,3 mm (0.12 in) Thick

060000-022 Roll Pin (2)

060131-006, 6 mm (0.25 in) Thick

060099-006 Bolt (2) & 060131-005 Flatwasher (2)

060131-008, 1.8 mm (0.07 in) Thick

17. Visually check to confirm that all cables connecting the power unit to the mainframe have been disconnected. Then carefully separate the power unit from the mainframe.

WARNING Lifting equipment with insufficient capacity and size may break or become unstable resulting In an unsafe condition. • Make certain the lifting equipment is of sufficient capacity and size to safely handle the mainframe. 19. Attach lifting equipment to the shipping bracket and also to the base of the mainframe. Make certain the lifting equipment is of sufficient capacity and size to safely handle the mainframe. Extreme care must be exercised during this procedure.

WARNING Load wheels must remain securely chocked throughout this entire procedure.

Crown 2005 PF15129-11 Rev. 12/08

TSP 6000 Series

M7.0-1960-010

437

LIFTING MECHANISM Mast 20. Carefully lift the mainframe. As the mast assembly becomes horizontal, block as shown in Figure 20987. Use a support that is rated to handle at least 4535 kg (10,000 lb). Disconnect lifting equipment from shipping bracket at top of mast assembly. DO NOT remove shipping bracket at this time.

22. Attach lifting equipment with weight distribution sling to third stage mast and extend mast approximately 355 mm (14 in), then set mast down onto support. Refer to Figure 20989.

Figure 20987 1

Load Wheel Chocks, Both Sides

Support

Figure 20989

21. Insert the pin tool through the hole at the top of the second stage mast and through the hole in the mainframe. This will prevent movement of the mainframe and second stage mast. Refer to Figure 20988.

Pin Tool

Support

Attach to Lifting Device

23. Slowly remove lifting bracket. Loosen one bolt ½ to 1 revolution, and then loosen the bolt on the opposite side an equal amount. Continue this process until there is no more tension on the lifting bracket bolts. Remove the lifting bracket completely. 24. Remove the bottom cover from the mainframe. 25. Remove and cap hydraulic mast hoses and hard lines at bottom of mainframe shown in Figure 20990. Label the hydraulic hoses.

Figure 20988

M7.0-1960-010

438

TSP 6000 Series

Crown 2005 PF15129-12 Rev. 12/08

LIFTING MECHANISM Mast 29. Remove springs on control cables from bracket through access at top of the third stage mast shown in Figure 20992. Then remove springs from cable clamps

Hydraulic Hose Fittings

Figure 20990

26. Remove connectors JC412, JC413 and JC414 from connector mount, then remove wire and pins from JC412 and JC413. Record position of wires in both connectors and label control cables. Refer to Figure 20991.

Figure 20992 1

Cable Clamps

Springs

Control Cables

Bracket

30. Mark position of large center hydraulic hose as shown. This mark will be used to line up hydraulic hose at reassembly to prevent twisting the hose. Refer to Figure 20993.

Mark Hydraulic Hose

Figure 20991

27. Remove control cables from bracket and drape down at bottom of the mainframe. 28. Remove access cover at top portion of third stage mast, and remove shipping bracket from top of mast.

Figure 20993

Crown 2005 PF15129-13 Rev. 12/08

TSP 6000 Series

M7.0-1960-010

439

LIFTING MECHANISM Mast 31. Disconnect and plug the large hydraulic hose through access opening at top section of third stage mast. Also plug hydraulic hard line to prevent leakage and contamination from getting into hydraulic cylinder.

34. Pull loose end of hydraulic hoses and control cables out top end of mast and drape them onto the floor. Separate hoses and cables as much as possible to prevent entanglement during mast separation.

32. Number the hydraulic hoses and control cables at top of mast. Refer to Figure 20994.

35. Loosen bolts on both sides of hose pulley assembly and carefully remove the shims noting their amount and location. Refer to Figure 20996. Shims

Figure 20996 Figure 20994

33. Remove hose retainer shafts at both ends of the hose pulley assembly on top of the second stage mast. Refer to Figure 20995.

36. After removing shims remove bolts and hose pulley assembly from mast. 37. Remove chain slack break switch assembly from mast. 38. Remove roll pins and dowel pins holding lift chains to top of mainframe. Do not remove or loosen nuts on chain anchors. Refer to Figure 20997.

Hose Retainer Shaft

Figure 20995

M7.0-1960-010

440

TSP 6000 Series

Crown 2005 PF15129-14 Rev. 12/08

LIFTING MECHANISM Mast 42. Remove bolt and rotate thrust roller cam shafts to their loosest position. Install bolts and secure both thrust roller shafts at their loosest position. 43. At the bottom of the third stage mast, mark the side thrust roller cam shaft location. Remove bolt and rotate thrust roller cam shafts to their loosest position. Install bolts and secure both thrust roller shafts in position. 44. Attach lifting equipment with weight distribution sling to third stage mast. Make sure that both support and lift can secure mast in position. Remove mast stops. Refer to Figure 20999.

Figure 20997

Mast Stop

39. Remove chains from chain anchors, feed chains down through chain pulley support at top of second stage mast and drape chains out end of mast. 40. Remove chain pulley support from top of second stage mast. 41. Mark location of both thrust roller shafts at the top of the second stage mast. Refer to Figure 20998.

Figure 20999

45. Raise mast just enough so the third stage is not in contact with the support. Make sure the pin tool is still holding the mainframe and second stage together. Then carefully move the third stage toward top of the mast. When the third stage is approximately 1 meter (3 ft) from the end of the mast, reposition the support so that it is just below the third stage mast and lower the mast down onto the support while still supporting the third stage with the lift and sling. Refer to Figure 21000.

Figure 20998 1

Side Thrust Roller Shaft

Bolt

Location Mark

Crown 2005 PF15129-15 Rev. 12/08

TSP 6000 Series

M7.0-1960-010

441

LIFTING MECHANISM Mast

Figure 21000 1

Load Wheel Chocks, Both Sides

Attach Sling, Chains, etc.

To Lifting Device

WARNING Make certain that the lifting equipment is attached to the third stage mast in such a manner that it will prevent the bottom of the mast from dropping when it clears the remaining mast assembly.Also make certain that the remaining mast is adequately supported so that it does not drop to the floor. Failure to do so could result in serious injury and damage to truck components. 46. Using the lifting device and sling, remove the third stage mast from the mast assembly. Make sure the control cables, hydraulic hoses and chains do not bind or become entangled with any other part of the remaining mast assembly. Set third stage mast on floor on top of four 100 x 100 mm (4 x 4 in) hardwood boards as shown. Stack two blocks on top of each other so that the third stage mast will be elevated and will not be resting on any of the hydraulic fittings. Refer to Figure 21001.

M7.0-1960-010

442

100 x 100 mm (4 x 4 in) Hardwood Blocks Figure 21001

47. Install lifting device and sling on second stage mast. 48. Remove pin tool from mast. 49. Loosen tension on side thrust rollers at bottom of the second stage mast and also at the top of the mainframe assembly in same manner previously described. 50. Raise mast just enough so the second stage is not in contact with the support. Then carefully move the second stage toward top of the mast. When the second stage is approximately 1 meter (3 ft) from the end of the mast, reposition the support so that it is just below the second stage mast and lower the mast down onto the support while still supporting the second stage with the lift and sling.

TSP 6000 Series

Crown 2005 PF15129-16 Rev. 12/08

LIFTING MECHANISM Mast WARNING Make certain that the lifting equipment is attached to the second stage mast in such a manner that will prevent the bottom of the mast from dropping when it clears the remaining mast assembly. Also make certain that the mainframe is adequately supported so that it does not drop to the floor. Failure to do so could result in serious injury and damage to truck components. 51. Using the lifting device and sling, remove the second stage mast from the mast assembly. Set second stage mast on floor on top of two 100 x 100 mm (4 x 4 in) hardwood blocks.

Roller Adjustment Column Rollers 1. Clean column roller studs. If any paint or rust is evident on studs, remove with emery cloth and lubricate with multi-purpose grease (Crown 063002-024). 2. Install column rollers with large radius of roller towards stud shoulder, see Figure 13045-01. Install new retaining rings.

4. At the bottom of second stage mast, with column rollers pushed against the stud shoulders and the second stage forced to one side, measure the distance on both sides between the column roller face and the web of the I-beam. 5. Divide the sum of these two gaps by 2 and place this amount of shim or gage, between the column roller and the web on one side of the mast. 6. Adjust the cam on the opposite side so that the thrust roller contacts the flange of the I-beam. 7. Remove the shim and adjust the other cam so the thrust roller contacts the flange of the I-beam. 8. Move the second stage up and down the mainframe. The thrust rollers should roll about 75% of the time or more, without heavy marking of the mast. 9. Fully retract the second stage and adjust cam shafts, at the top of the first stage, to their loosest setting. 10. Repeat steps 4 thru 8 to adjust the top thrust rollers.

Installing Second Stage Mast TF and TN (Without Sufficient Overhead Clearance)

WARNING Make certain the lifting equipment is of sufficient capacity and size to safely handle the second stage mast. Lifting equipment with insufficient capacity and size may break or become unstable resulting in an unsafe condition. Figure 13045-01 1

Large Radius Towards Mounting Stud

Second Stage Mast

No Shims

Column Roller

1. Attach lifting equipment to second stage mast. Make certain lifting equipment is attached in such a manner that will keep the mast parallel with the mainframe during installation. The use of a spreader bar or other weight-balancing type arrangement is recommended.

Side Thrust Rollers TF and TN

WARNING

3. Extend the second stage to the mainframe stops and adjust cam shafts to their loosest setting. Apply a light film of grease to both ends of cam shafts before inserting.

Crown 2005 PF15129-17 Rev. 12/08

Make certain mainframe supports are positioned properly and both load wheels are chocked. Control the mainframe and second stage mast to prevent unnecessary weight shifting.

TSP 6000 Series

M7.0-1960-010

443

LIFTING MECHANISM Mast 2. With the mainframe properly blocked in the horizontal position, align the second stage mast with the mainframe. Then carefully slide the second stage mast onto the mainframe and install poly stops on mainframe. Refer to Figure 13042-01. 3. Install the shipping bracket, originally shipped with truck, on top of the second stage mast and secure it to the mainframe using the mounting hardware that was furnished with the bracket. Refer to Figure 13040-01. 4. Attach lifting equipment to the shipping bracket at the top of the mast and also to the base of the mainframe. Make certain the lifting equipment is of sufficient capacity and size to safely handle the mainframe and platform assembly. The weight of the mainframe and platform assembly is approximately 3630 kg (8000 lb). Extreme care must be exercised during this procedure.

WARNING Load wheels must remain securely chocked throughout this procedure. 5. Carefully raise the mainframe until the mast is in a vertical position. Then place blocks beneath mainframe as shown in Figure 13036-01. Make certain to secure the assembly in a manner that will prevent the mast from going beyond a vertical position. 6. Remove lifting equipment from mainframe and shipping bracket on second stage mast. Then remove shipping bracket and return bracket and associated hardware to storage for future use. 7. Position power unit in proper alignment with mainframe and platform assembly. Place blocks beneath power unit and chock drive wheel.

Figure 20932 1

060131-007, 3 mm (0.12 in) Thick

060131-006, 6 mm (0.25 in) Thick

060131-008, 1.8 mm (0.07 in) Thick

9. Using a torque wrench, manually tighten the mounting bolts to a torque value of 305 Nm (225 ft lb) following the sequence shown in Figure 20933. Then, following the same sequence, tighten the mounting bolts to a torque value of 435 Nm (320 ft lb). Make certain that the mounting bolts are tightened to a torque value of 43 Nm (320 ft lb).

8. Install mounting bolts, two at top, 060099-007, and six at bottom, 060131-005, through power unit with bolt heads pointing towards power unit. Install shims, 060131-006 thru -008, between power unit and mainframe. Make certain shims are installed in correct location. Then install flatwashers 060131-005, and hex nuts 060059-035, on mounting bolts. Refer to Figure 20932.

M7.0-1960-010

444

TSP 6000 Series

Crown 2005 PF15129-18 Rev. 12/08

LIFTING MECHANISM Mast 15. If reservoir was not drained, replace non-vented cap on reservoir with the vented filler and breather cap that was previously removed. Store nonvented cap for future use.

Torque Value and Sequence

16. Check oil level in hydraulic reservoir. If necessary, fill to the proper level with an approved lubricant. Refer to Hydraulic System maintenance section for hydraulic reservoir information. 17. Install batteries and replace power unit covers and doors.

WARNING Make certain all stops and safety devices are in place before cycling mast to check for proper operation. Figure 20933

Torque bolts in the sequence shown in the following steps: –

Step 1: 305 Nm (225 ft lb)

–

Step 2: 435 Nm (320 ft lb)

–

Step 3: Verify torque of 435 Nm (320 ft lb)

18. Run operational check.

Installing Second Stage Mast TF and TN (With Sufficient Overhead Clearance)

10. Install lift cylinders in mainframe. Refer to Cylinders maintenance section for cylinder installation procedures. 11. Make certain that all electrical cables, hydraulic hoses, lift chains, mast cables, wire guidance cable (if applicable), etc., are properly connected. 12. Install cover (1) on top of mast, see Figure 13038-01. Attach chain (2) to cover and secure cover to mast. 13. Install platform on mainframe. Refer to Platform maintenance section for platform installation procedure. 14. Install load handler assembly. Refer to Platform maintenance section for load handler installation procedure.

WARNING Lifting equipment with insufficient capacity and size may break or become unstable resulting in an unsafe condition. • Make certain the lifting equipment is of sufficient capacity and size to safely handle the second stage mast. 1. Attach lifting equipment to second stage mast. 2. Raise second stage mast into position above mainframe. Then carefully lower the second stage mast onto the mainframe and install poly stops on mainframe. Refer to Figure 13042-01. 3. Remove lifting equipment from second stage mast. 4. Install lift cylinders in mainframe. Refer to Cylinder maintenance section for cylinder installation procedures. 5. Make certain that all electrical cables, hydraulic hoses, lift chains, mast cables, wire guidance cable (if applicable), etc., are properly connected. 6. Install cover (1) on top of mast. Attach chain (2) to cover and secure cover to mast. Refer to Figure 13038-01. 7. Connect batteries.

Crown 2005 PF15129-19 Rev. 12/08

TSP 6000 Series

M7.0-1960-010

445

LIFTING MECHANISM Mast WARNING Make certain all stops and safety devices are in place before cycling mast to check for proper operation. 8. Run operational check.

Installing Second and Third Stage TT Mast WARNING Lifting equipment with insufficient capacity and size may break or become unstable resulting in an unsafe condition. • Make certain the lifting equipment is of sufficient capacity and size to safely handle the second stage mast. 1. Attach lifting equipment to second stage mast. Make certain lifting equipment is attached in such a manner that will keep the mast parallel with the mainframe during installation. The use of a spreader bar or other weight balancing type arrangement is recommended.

WARNING Make certain mainframe supports are positioned properly and both load wheels are chocked.Control the mainframe and second stage mast to Prevent unnecessary weight shifting. 2. With the mainframe properly blocked in the horizontal position, align the second stage mast with the mainframe. Then carefully slide the second stage mast onto the mainframe.

6. Divide the sum of these two gaps by 2, and place this amount of shim gage between the column roller and the web on one side of the mast. 7. Adjust the cam on the opposite side so that the thrust roller contacts the flange of the I-beam. A 10 mm (0.394 in) square has been put in the head of the cam shaft to accept a 9.53 mm (0.375 in) square socket extension. 8. Remove the shim and adjust the other cam so the thrust roller contacts the flange of the I-beam. 9. Use a grease pencil to put a mark on the side thrust rollers. Move the second stage up and down the mainframe. The thrust rollers should roll 100% of the time, without marking of the mast. 10. Fully retract the second stage and adjust cam shafts, at the top of the mainframe, to their loosest setting if they are not already at the setting. 11. Repeat steps 5 through 9 to adjust the top thrust rollers. 12. With the second stage mast fully retracted secure it in position using the pin tool. 13. Attach lifting equipment to the third stage mast. Make certain lifting equipment is attached in such a manner that it will keep the third stage mast parallel with the rest of the mast during assembly. The use of a spreader bar or other weight balancing type arrangement is recommended. 14. With the mainframe and second stage mast assembly properly blocked in the horizontal position, align the third stage mast with the assembly. Carefully slide the third stage mast onto the assembly. 15. Install mast stop blocks onto second stage mast, use blue thread locking adhesive, 061004-026, on all eight bolts. Torque bolts to 247 - 267 Nm (182 197 ft lb).

2nd stage mast side thrust roller adjustment 3. With lifting equipment still attached and the support holding the mainframe level, position the bottom of the second stage mast approximately 810 to 915 mm (32 to 36 in) below the top of the mainframe. 4. Adjust the side thrust roller cam shafts to their loosest setting if they are not already at that point.

Mast Stop

5. At the bottom of the second stage mast, with column rollers pushed against the stud shoulders and the second stage forced to one side, measure the distance on both sides between the column roller face and the web of the I-beam. M7.0-1960-010

446

TSP 6000 Series

Figure 20999

Crown 2005 PF15129-20 Rev. 12/08

LIFTING MECHANISM Mast 3rd stage mast side thrust roller adjustment 16. Extend the third stage mast until it contacts the mast stop blocks and adjust cam shafts to their loosest setting if they are not already in that position.

Hydraulic Hose Fittings

17. At the bottom of the third stage mast, with column rollers pushed against the stud shoulders and the third stage forced to one side, measure the distance on both sides between the column roller face and the web of the I-beam. 18. Divide he sum of these two gaps by 2, and place this amount of shim gage between the column roller and the web on one side of the mast. 19. Adjust the cam on the opposite side so that the thrust roller contacts the flange of the I-beam. 20. Remove the shim and adjust the other cam so the thrust roller contacts the flange of the I- beam. 21. Use a grease pencil to put a mark on the side thrust rollers. Move the third stage up and down the mainframe second stage mast assembly. The thrust rollers should roll 100% of the time, without marking of the mast. 22. Install the chain pulley support on top of the second stage mast and torque bolts to 247 - 267 Nm (182 - 197 ft lb). 23. Feed chains through chain anchor support and install on chain anchors at top of mainframe. 24. Install chain slack break switch assembly on mainframe. 25. Install hose pulley assembly on top of second stage mast making sure shims are in same position as removed. Torque bolts to 247 - 267 Nm (182 - 197 ft lb). 26. Install hydraulic hoses and control cables back over hose pulley assembly in same positions as removed. Do not twist hoses or cables during installation. 27. Install hose retainer shafts at both ends of the pulley assembly bracket and secure. 28. Connect large hydraulic hose to secondary cylinder. DO NOT twist hose, used reference mark to assure that hose is not twisted or rotated.

Figure 20990

30. Install two hydraulic hoses in positions shown. Do not twist hoses, try to keep hoses as neutral as possible. 31. Feed electrical cables to bottom of mainframe close to termination point on right side of mainframe. 32. Install two springs, previously removed, onto control cable grips and bracket at top of mainframe. Adjust cable grips so the springs are extended approximately 140 mm (5.5 in). Secure springs to cable grips with wire ties. 33. Install connectors JC412 and JC413 back onto appropriate control cables. 34. Install connectors JC412, JC413 and JC414 into connector mount and secure in position with retainer, previously removed in Step 26. 35. Install bottom plate onto bottom of mainframe. 36. Install shipping bracket on top of mast assembly using mounting hardware that was originally supplied with bracket. Use a crow bar through the access hole at top of third stage mast and into hole in tab of second stage mast to collapse mast if needed. Remove pin tool from mainframe and second stage mast after shipping bracket has been installed. Refer to Figure 21002.

29. Feed the two smaller hydraulic hoses through to bottom of mainframe. Pull out the bottom and route to connections shown in Figure 20990.

Crown 2005 PF15129-21 Rev. 12/08

TSP 6000 Series

M7.0-1960-010

447

LIFTING MECHANISM Mast prevent the mast from going beyond a vertical position.

Figure 13036-01 Figure 21002 1

Hole at Top of 3rd Stage Mast

Tab is Part of 2nd Stage Mast

Block Both Sides

Load Wheel Chocks Both Sides

39. Remove lifting equipment from mainframe and shipping bracket on top of mast. Then remove shipping bracket and return bracket and associated hardware to storage for future use.

WARNING Lifting equipment with insufficient capacity and size may break or become unstable resulting In an unsafe condition. • Make certain the lifting equipment is of sufficient capacity and size to safely handle the mast assembly. 37. Attach lifting equipment to shipping bracket at the top of the mast assembly and also to the base of the mainframe. Make certain the lifting equipment is of sufficient capacity and size to safely handle the mast assembly. The lifting equipment must be able to handle a minimum weight of 4535 kg (10,000 lb). Extreme care must be exercised during this procedure.

40. Position power unit in proper alignment with mast assembly. Place blocks beneath power unit and chock drive wheel. 41. Install mounting bolts, two at top 060099-007, six at bottom 060099-008, and shims 060131-005, through power unit with bolt heads pointing towards power unit. 42. Install shims, 060131-006 through -008, between the power unit and mainframe. Make certain that the shims are the same ones that were previously removed and that they are put in the same position. Then install flat washers 060131-005, and hex nuts 060059-035, on the mounting bolts in position shown. Refer to Figure 20932.

WARNING Load wheels must remain securely chocked throughout this procedure. 38. Carefully raise mainframe until mast assembly is in a vertical position. Then place blocks beneath the mainframe as shown in Figure 13036-01. Make certain to secure the assembly in a manner that will

M7.0-1960-010

448

TSP 6000 Series

Crown 2005 PF15129-22 Rev. 12/08

LIFTING MECHANISM Mast Torque bolts in the sequence shown in the following steps: –

Step 1: 305 Nm (225 ft lb)

–

Step 2: 435 Nm (320 ft lb)

–

Step 3: Verify torque of 435 Nm (320 ft lb)

44. Install primary lift cylinders on mainframe, refer to Cylinder maintenance section for installation procedure. 45. Make certain that all electrical cables, hydraulic hoses, lift chains, mast cables, wire guidance, etc. are properly connected. 46. Install cover on top of third stage mast. Make sure that chain is attached to cover and to mast. 47. Install platform on mast assembly, refer to Platform maintenance section installation procedure. 48. Install load handler assembly onto platform, refer to Platform maintenance section for installation procedure. Figure 20932 1

060131-007, 3 mm (0.12 in) Thick

060131-006, 6 mm (0.25 in) Thick

060131-008, 1.8 mm (0.07 in) Thick

43. Using a torque wrench, first tighten the mounting bolts to 305 Nm (225 ft lb) in the sequence shown. Next tighten all 8 bolts to 435 Nm (320 ft lb) in the same sequence, then verify the 435 Nm (320 ft lb) torque on each bolt. Refer to Figure 20933.

49. Raise platform a sufficient amount that the chain anchors at the bottom of the third stage mast can be accessed, do not raise platform above free lift stage. Block platform as described in the Control of Hazardous Energy section of this manual. 50. Adjust chain anchors at bottom of the third stage mast through the opening shown. The chain anchors should be adjusted so the distance from top of cylinder mount shelf is 381 mm (15.0 in) above the mainframe top plate. Adjust both chain anchors in equal increments to maintain a balanced chain load. Refer to Figure 21006.

Torque Value and Sequence

Figure 20933

Crown 2005 PF15129-23 Rev. 12/08

TSP 6000 Series

M7.0-1960-010

449

LIFTING MECHANISM Mast

Figure 21006 1

Adjust Chain Anchors Here

Cylinder Mount Shelf

Main Frame Top Plate

51. Install access cover on third stage mast, use original hardware for installation. 52. If reservoir was drained, fill with approved lubricant as specified in Planned Maintenance, Lubricants maintenance section. If reservoir was not drained, replace non-vented cap with vented filler/breather cap and store non vented cap for future use. 53. Check oil level in hydraulic reservoir. If level is low, fill with approved lubricant. 54. Bleed primary and secondary cylinders. See Cylinder maintenance section for procedure.

WARNING Make sure all stops and safety devices are in place before cycling mast to check proper operation. 55. Install battery and replace power unit covers and doors as required. 56. Run operational check.

M7.0-1960-010

450

TSP 6000 Series

Crown 2005 PF15129-24 Rev. 12/08

LIFTING MECHANISM Hose Take-Up Cable

Hose Take-Up Cable The hose take-up cable is routed through a series of pulleys located in the mast. As the mast is raised or lowered, the cable maintains constant tension on the hose take-up assembly keeping the hoses and cables from becoming slack. Refer to Figure 21336.

3. Loosen the clamp holding the adjustor in position and rotate the adjustor so that full cable tension adjustment is available for the replacement cable. 4. Remove the cover on the top of the mainframe. 5. Attach a cable or chain to the pulley plate mounting bracket and secure. A hole is located in the bracket for this purpose. Refer to Figure 21337.

Figure 21336 1

Under cover on mast

Adjustor

Pulley (Part of Take-Up Assembly)

Take-Up Assembly Stop

Poly Stop

Yoke

Pulley mounted at top of mast

Pulley on bracket fastened to primary lift cylinder

Figure 21337

Cable Removal If the cable becomes worn, or if it breaks, follow the procedure outlined below to replace the cable.

Pulley Plate Mounting Bracket

Primary Lift Cylinder Assembly

Mounting Bolt

1. Disconnect battery and chock load wheels.

Pulley Bracket with Anchor Access Hole

2. Remove cable adjustor access cover located on the back of the mast.

6. Remove the mounting bolt in the top of the bracket.

Crown 2005 PF15127-1 Rev. 1/09

7. The pulley plate mounting bracket is assembled into a V slotted bracket on the bottom of the pri-

TSP 6000 Series

M7.0-1960-100 01 Rev. 1/09

451

LIFTING MECHANISM Hose Take-Up Cable mary lift cylinder. Using the cable or chain attached to the bracket, allow the pulley bracket to lower out of the V bracket. Then lift the bracket up and out of the mast. Refer to Figure 21338.

4. Assemble bolt into pulley bracket and tighten. 5. Remove cable or chain from bracket. 6. Route take-up cable through remaining pulleys and secure to adjustor. 7. Using a spanner wrench (Crown part number 108641), adjust cable tension so that there is 6 - 9 mm (0.25 - 0.38 in) clearance between the hose take-up assembly stop and poly stop when platform is completely lowered.

Figure 21338 1

V Slot

Pulley Bracket

Cable

Figure 21339

8. Disassemble cable and remove from mast. Cable Installation 1. Attach the cable to the yoke at the top of the mast.

Adjustor

Take-Up Assembly

6 - 9 mm (0.25 - 0.38 in) clearance when platform is lowered

Poly Stop

Yoke

2. Using the hole in the top of the pulley plate mounting bracket, attach a cable or chain to the bracket. 3. Loop the hose take-up cable around the pulley and lower the bracket into the mast. Hook the bracket into the V slot on the bottom of the primary lift cylinder. Secure chain or cable.

M7.0-1960-102 01 Rev. 1/09

452

CAUTION Adjusting cable tension so that there is greater than 9 mm (0.38 in) clearance between hose take-up assembly stop and poly stop may result in premature wear of the take-up assembly guide.

TSP 6000 Series

Crown 2005 PF15127-2 Rev. 1/09

LIFTING MECHANISM Load Wheels

Load Wheels The following procedures are for replacement of load wheels and lathe cutting load wheels to ensure wheels are of equal diameter and concentricity to ensure proper operation, comfort and productivity.

Load Wheel Removal 1. Lower platform and forks. 2. Chock one load wheel. 3. Raise main frame enough to remove load wheel. Refer to Control Of Hazardous Energy Lockout/Tagout for lifting and blocking. 4. Remove load wheel hub cap. 5. Remove load wheel from truck. Figure 21272

Tire Replacement 1

1. Press hub out of tire to be replaced.

NOTE Do not press hub through old tire directly into new tire in one operation. This method is more likely to cause hub misalignment resulting in premature tire failure. 2. Inspect load wheel hub for damage and replace if needed. 3. Place new tire on a flat, level steel plate, shim plate as required. This will insure an even distribution of force and pressure when hub is pressed into the tire. 4. Position hub on tire. 5. Place a cylindrical steel plate, 28 mm ± 1 mm (1.12 in, ± 0.04 in) thick with an outside diameter (O.D.) of slightly less than the outside diameter of the hub. This will allow the hub to be recessed into the tire 28 mm ± 1 mm (1.12 in, ± 0.04 in). Refer to Figure 21272.

Hub

Part of Press

Steel Plate

Tire

Steel Plate Work Surface

6. Apply a light film of oil to the outside of hub. 7. Press hub into tire. 8. Check for proper hub alignment and depth.

Lathe Cutting The new load wheel must be sized down to a diameter of 355.6 mm ± 1.5 mm (14.0 in ± 0.06 in) after the tire is pressed onto the hub.

NOTE The tire can not be lathe cut before the hub is pressed in due to requirements for hub-bearing bore concentricity to tire outside diameter.

Crown 2005 PF15117-1 Rev. 1/09

TSP 6000 Series

453

LIFTING MECHANISM Load Wheels 2. Using outside diameter calipers as a measuring guide, trim wheels down to 355.6 mm ± 1.5 mm (14.0 in ± 0.060 in) in diameter. Approximately 6.3 mm (0.25 in) needs to be trimmed from tire. Refer to Figure 21273.

NOTE Do not try to remove full amount from tire in first cutting. Remove small amounts and measure frequently.

Figure 21273 1

Smooth cast urethane surface to be this side

Press flush on this side

Break sharp corners

3. The outside tire diameter to be concentric to inside bearing diameter within 1.0 mm (0.040 in) total indicator run out. Note: It is important that both load wheels are the same in order to prevent premature wear on tires and for proper operation, comfort and productivity.

TSP 6000 Series

454

Crown 2005 PF15117-2 Rev. 1/09

LIFTING MECHANISM Lift Chains

Lift Chains

•

Lift chains are highly important components on fork lift trucks. The chain system on your mast was designed for efficient, reliable transmission of lifting force from hydraulic cylinder to the forks. Safe, uninterrupted use of your lift truck depends on the proper care and maintenance of the lift chains.

Do not repair chain(s) by cutting out the worn section and splicing in a new piece. If part of a chain is worn, replace both lift chains. If truck has a matched set of lift chains replace both chains at same time.

Most complaints of unsatisfactory chain performance can be traced directly to inadequate maintenance. Highly stressed precision chains require periodic maintenance to deliver maximum service life.

Inspection After every 250 hours of truck operation, lift chains should be inspected and lubricated. When used in an extremely corrosive environment, inspect chains every 100 working hours. During inspection, check for the following:

Roller and Chain Wear Scale

Wear As the chain flexes on and off the pulleys, the joints gradually wear. The stretch a chain develops in service is due to material being worn off of pin outside diameter and pin hole inside diameter on the inside plates.

•

Chain wear can be measured by using a 106440 wear scale or a steel tape, Refer to Figure 16845-01.

•

When chains have elongated 3%, as represented on scale A (19 mm (0.75 in) or 25 mm (1.0 in) pitch chain) or scale B (16 mm (0.625 in) pitch chain) of the wear scale, they should be discarded.

•

On chain with 19 mm (0.75 in) between pins, for example, 305 mm (12 in) of chain contains 16 pitches or links. When 16 pitches measure 314 mm (12.375 in) the chain should be replaced.

•

On chain with 16 mm (0.625 in) between pins, 20 pitches or links equal 318 mm (12.5 in). When 20 pitches measure 327 mm (12.875 in) the chain should be replaced. Crown currently uses 16 mm (0.625 in) pitch (20 links in 318 mm (12.5 in)), 19 mm (0.75 in) pitch (16 links in 305 mm (12 in)) and (1.0 in) pitch (12 links in 305 mm (12 in)) chain.

•

When checking chain wear, be sure to measure a segment of chain that operates over a pulley.

Crown 2005 PF15090-1 Rev. 1/09

TSP 6000 Series

Figure 16844-01

M7.5-1960-001 01 Rev. 1/09

455

LIFTING MECHANISM Lift Chains

Corroded Chain (With Stress, Corrosion Cracks)

Figure 16846-01

With forks lowered check either front or rear of pulley for chain wear

Heavy motor oil serves both as a joint lubricant and corrosion inhibitor. During inspection, carefully examine external chain surfaces for the presence of an oily film. Under certain operating or environmental conditions it may be necessary to lubricate chains more frequently than 250 hour intervals. In all cases, the external surface of the chain must be protected with a film of oil.

Figure 16845-01

Rust and Corrosion Chains used on lift trucks are highly stressed precision components. It is very important that as-manufactured ultimate strength and fatigue strength be maintained throughout the chain service life. Corrosion will cause a major reduction in the load carrying capacity of lift chain or roller chain because corrosion causes side plate cracking. It is extremely important to protect lift chains from corrosion, whether in service or in storage. The initial factory lubricant on chains is an excellent rust and corrosion inhibitor. Factory lubricant is applied in a hot dip tank to insure complete penetration into the joint. Do not steam clean or degrease new chains. After the chain has been placed in service, factory lubricant must be supplemented by a maintenance lubrication program. Refer to the Lubrication and Adjustment section for your particular truck series or the lubrication information later in this section.

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Corroded chains should be inspected for cracked plates. Outside plates are particularly susceptible to stress corrosion cracking. If chains are heavily rusted or corroded they should be removed from the mast for a thorough inspection for cracked plates. If plates are cracked, both chains on the truck must be replaced. Lubricate chains when they are reinstalled on the mast.

Cracked Plates The most common cause of plate cracking is fatigue failure. Fatigue is a phenomenon that affects most metals and many plastics. After many repeated heavy loads the plates may crack and the chains will eventually break. Fatigue Cracks

Figure 16847-01

Fatigue cracks are almost always found through the pin holes perpendicular to the pitch line, Refer to Figure 16847-01. Contrast this failure mode to the random failures caused by stress-corrosion cracking. Refer to Figure 16846-01. If any fatigue cracks are discovered during planned maintenance (PM) inspections, both lift chains should be replaced. Many apparently sound

TSP 6000 Series

Crown 2005 PF15090-2 Rev. 1/09

LIFTING MECHANISM Lift Chains plates will be on the verge of cracking, making chain failure very likely.

Protruding and Turned Pins

Tight Joints All joints in lift chain should flex freely. Tight joints resist flexure, increase internal friction, thus increasing chain tension required to lift a given load. Increased tension accelerates wear and fatigue problems. Refer to Figure 16848-01. Tight Joints

Figure 16849-01

Chain Side Wear Figure 16848-01

•

Bent pins or plates,

A continuous wear pattern on pin heads and outside plates indicates misalignment. Misalignment can be caused by two different factors: unequal chain tension or nonalignment between pulleys and chain anchors.

•

Rusty joints,

Unequal Chain Tension

•

Peened plate edges.

•

Tight joints in lift chains can be caused by:

Lubricate rusty chains and replace chains that appear bent or peened. Peening of plate edges may be caused by worn pulleys, unusually heavy loads, or chain sliding past a guide or obstruction in the mast.

Protruding or Turned Pins Heavily loaded chains operating with little lube generate tremendous friction between pin and plates or pin and bushing in roller chain. In extreme cases, the frictional torque in the joint can actually turn pins in the press-fit outside plates. If chain is allowed to operate in this condition, the pins slowly work out of the chain, causing chain failure. Turned pins can be quickly spotted because the flats on the V heads are no longer in line. Refer to Figure 16849-01, pin has turned 45°. Chains with turned or protruding pins should be replaced immediately. Note: Never attempt to repair the chain by driving pins back into the chain.

When a lift chain is installed or adjusted, care should be taken to load the chains evenly. When changing fork heel height or platform height for example, the chain anchors should be loosened until both forks come in contact with the floor. At this point both chains should display the same tension or slack. The chain anchor nuts should be tightened an equal number of revolutions on both chain anchors to put equal tension on chains. When the desired height setting is achieved the locking nut should be tightened to secure setting.

Non Alignment of Lifting Components

•

Non alignment of the pulley and chain due to incorrect shimming of the mast or bent or damaged mast or cylinder components can also contribute to chain side wear. A check for this condition is to place the truck on a level area in your maintenance area. After supporting the fork carriage, disconnect each end of the lift chain at the chain anchor and visually inspect its alignment with the anchor slots.

Lift Chain Lubrication The most important consideration in field maintenance of lift chains is LUBRICATION. Hard working, heavily loaded chains cannot be expected to give satisfactory Crown 2005 PF15090-3 Rev. 1/09

TSP 6000 Series

M7.5-1960-003 01 Rev. 1/09

457

LIFTING MECHANISM Lift Chains wear life without scheduled periodic lubrication. Like all bearing surfaces, the precision-manufactured, hardened-steel, joint-wearing surfaces require a film of oil between mating parts to prevent rapid wear. Maintaining an oil film on all chain surfaces will:

•

Minimize joint wear i.e. chain stretch.

•

Prevent corrosion.

•

Reduce the possibility of pin turning.

•

Minimize tight joints in roller chain.

•

Promote smooth, quiet chain action.

•

Lower chain tension by reducing internal friction in the chain system.

dry with metal-to-metal contact between pins and plates. At 250 hour intervals, clean chains to remove accumulation of dirt and lubricate immediately. Do not steam clean chains. Lubricate

Heavy motor oil is an excellent chain lubricant; laboratory wear tests show SAE 40 oil to have greater ability to prevent wear than SAE 10 oil. Also, SAE 40 oil is superior to hydraulic fluid or automatic transmission fluid. Generally, the heaviest, highest viscosity oil that will penetrate the joint works best. Lab wear testing shows dry film lubes to be less effective in preventing joint wear than fluid petroleum based products. Some aerosol spray lubes, such as Crown part number 363115-001, are effective, more convenient and less messy than applying motor oils. Whatever method is used, the oil must penetrate the chain joint to prevent wear. Applying oil to external surfaces will prevent rust, but oil must flow into the live bearing surfaces for maximum wear life. Refer to Figure 16850-01. Apply oil to chains with a narrow paint brush. A plastic liquid detergent bottle makes a handy lube applicator. Flood the chain with oil over its entire length every lubrication inspection period. Frequency of lubrication will vary with operating conditions and environment. The best estimate of lube period is 250 hours actual operating truck time. Trucks parked outdoors, used in freezers or trucks in extremely severe service, may require more frequent lubrication to maintain an oil film on all chain surfaces. In dusty operating conditions, lubed chains will gather dust. Even under these conditions wear life will be greatly improved by periodic lubrication. Joints may acquire a paste made up of oil and dirt, but joint wear will still be much less than if the chain is allowed to run

M7.5-1960-003 01 Rev. 1/09

458

Figure 16850-01

Lift Chain Replacement The first step in chain replacement is to find the chain part number in your service manual parts list. An important factor in ordering replacement chain from the truck manufacturer is that special chains may be specified for your truck with certified minimum ultimate strength. If the unit is equipped with two strands, replace chains as a pair. It will be virtually impossible to maintain uniform loading between the strands if a new chain is put into service opposite an old chain. The joints in the old chain will have worn through the hardest layer of the case-hardened pin. Therefore, the wear rate on the old chain will be greater than that on the new chain, greatly complicating the problem of maintaining equal chain tension. The new chain will wear more slowly, causing it to bear the major portion of the load, resulting in premature wear and fatigue failure. Never steam clean or degrease new chains. The manufacturer's grease is effective in reducing wear and corrosion. If the original factory lubricant is dried out or wiped off, soak the new chain in heavy engine oil for at least 0.5 hour prior to installing on truck.

TSP 6000 Series

Crown 2005 PF15090-4 Rev. 1/09

LIFTING MECHANISM Lift Chains After the old chains have been removed from the mast, very carefully inspect chain anchors and sheaves. Broken, cracked, or worn anchors must be replaced. Replace worn sheaves, and check sheave bearings for wear. Do not paint new replacement chain before or after it has been installed. Paint will help prevent corrosion, but will prevent oil from reaching the pin surface for good joint lubrication. Install the new chains, using new anchor pins. Old pins may contain invisible fatigue cracks that could lead to pin failure. After chains have been connected to the anchors, adjust chain tension to obtain proper fork or platform lower height. Correct chain installation and mast adjustment will increase chain service life.

Chain Anchors and Pulleys An inspection of the chain system should include a close examination of chain anchors, anchor tension devices and pulleys.

•

Pin punch with a diameter slightly less than the pin diameter, hammer or pressing equipment.

Disconnect Procedures Refer to Figure 16851-01. 1. Grind the top head of the pin flush with the pin link plate. Be careful not to grind or damage the pin link plate. 2. Position the support ring over opening of the work surface. The support ring serves to support the bottom pin link plate and avoids damage to chain components while driving the pin through the chain. 3. Stand the chain on its side and seat pin in the support ring. 4. Remove the pin from the chain through the top pin link plate.

Check chain anchors for wear, breakage, and radial misalignment. Anchors with worn or broken fingers should be replaced. Anchors should be adjusted to eliminate twisting or other misalignment in the chain. When chain is misaligned, load is not distributed uniformly between the plates - prolonged operation will result in premature fatigue failure. Pulleys with badly worn flanges and outside diameter should be replaced. Heavy flange wear indicates chain misalignment. Investigate cause by checking chain tension and mast shimming. Figure 16851-01

Leaf Chain Disconnect

To minimize the risk of damaging, cracking, etc. the chain, refer to the following when disconnecting leaf chain. Equipment Required:

•

A sturdy work surface with an opening slightly greater than the pin diameter, and should be thick enough to allow the pin to extend beneath the work surface as it is driven through the bottom pin link plate.

•

A support ring such as a flatwasher with an inside diameter slightly greater than the pin diameter and a height equal to the head height of the pin.

•

Grinding wheel.

Crown 2005 PF15090-5 Rev. 1/09

Support Ring

Grind pin flush with link plate

Grinding Wheel

Pin Link Plate

Work Surface Knockout Aperature

TSP 6000 Series

M7.5-1960-003 01 Rev. 1/09

459

LIFTING MECHANISM Fork Inspection

Fork Inspection Chart 1

DANGER

Standard Fork Blade Thickness

The following causes of fork failure may mean loss of equipment, damaged materials, bodily injury or loss of life. • At each planned maintenance interval an inspection and measurement of the forks must be made to check for wear, overload, fatigue, bends, etc.

WARNING Use the proper fork for which it was designed to be used. • Avoid using fork extensions.

• •

Do not modify forks. Only qualified personnel should make such repairs. Inspect forks visually each work day.

Allowable 10% Wear Fork Blade Thickness

31.5

1.25

28.5

1.12

38.0

1.50

35.0

1.38

44.5

1.75

39.5

1.56

51.0

2.0

46.0

1.80

57.0

2.25

51.0

2.0

63.5

2.50

57.0

2.25

If using the fork wear calipers refer to the following:

Blade Measurement The fork wear calipers have two measuring points or jaws. The inside jaws measure 10 percent less than the outside jaws.

WARNING If the fork locking pin is not fully engaged, the fork could become unintentionally disengaged.

Abrasion Abrasion gradually reduces the thickness of the fork. Be sure the fork thickness is up to standard. Do not allow forks to rub the floor during normal operation, if forks do rub floor, check lift chain adjustment. Fork wear at the heel and at the hanger bore must not exceed 10 percent of the original thickness. At this point forks are adequate for approximately 80 percent of rated capacity. Refer to Chart 2 (Figure 21298). Crown has a fork wear calipers (part no. 107330) available for use or a measuring instrument such as a vernier or machinist six inch scale may be used. For allowable fork blade wear thickness, refer to Chart 1.

Figure 16854-01 1

Outside Jaws 100% (Fork Shank)

Inside Jaws 90% (Fork Blade)

To set the outside jaws, measure the thickness of the middle of the shank as this point receives almost no wear. Set the calipers to the feel of the shank by lightly tapping on them with a metal object. Care should be taken when using the calipers to hold them square across the shank or an incorrect reading will result.

M7.8-1960-001 02 Rev. 1/10

460

TSP 6000 Series

Crown 2005 PF15092-1 Rev. 1/10

LIFTING MECHANISM Fork Inspection

Figure 16857-01 1

Fork Blade cross section

Hanger Bore Measurement Figure 21294 1

Fork Blade

Fork Shank

Hanger

Measure here to set outside jaws

To check for elongation and wear of the hanger bore, the outside jaws of the fork wear calipers are used by rotating the legs of the calipers so that the jaws are on the outside.

Figure 21295 1 Figure 16856-01 1

Fork Shank cross section

When the outside jaws are set, check to see if the inside jaws of the calipers pass over the flanks of the fork blade at any point between the end of the taper and the heel of the fork blade. After checking the blade, recheck the caliper setting by measuring the shank again making sure the setting was not inadvertently changed.

Crown 2005 PF15092-2 Rev. 1/10

Use outside jaws for bore measurement

Place the outside jaws into the hanger bore and locate the largest diameter of the bore, this should be along the vertical axis, by rotating the calipers 180 degrees. Set the jaws to the feel of the bore by lightly tapping on them with a metal object. Be careful to hold the calipers square across the bore of the hanger or an incorrect reading will result.

TSP 6000 Series

M7.8-1960-002 02 Rev. 1/10

461

LIFTING MECHANISM Fork Inspection After the jaws are set, remove caliper and using a measuring instrument such as a verniers or machinist six inch scale, measure across the outside jaws. If the jaws measure more than 50 mm (2.0 in), replace fork. Rotate Calipers 180°

Percentage Reduction in Fork Blade Thickness

Figure 21296

Percentage Remaining of Specified Fork Capacity Figure 21298

M7.8-1960-003 02 Rev. 1/10

462

TSP 6000 Series

Crown 2005 PF15092-3 Rev. 1/10

LIFTING MECHANISM Fork Inspection Overloading

Bent or Twisted Forks

Know the capacity of the forks and truck. The fork capacity and load center is stamped on the fork, refer to Figure 21297. Overloading can cause permanent deformation or serious fatigue conditions.

Overloading, glancing blows against solid objects or picking up loads unevenly can bend or twist a fork, making fork replacement necessary. The maximum allowable difference in fork tip elevation from one fork to another is 3% of the fork length.

Location of Capacity and Load Center Rating

The angle between the top of the fork (blade) to the back surface of the vertical leg (shank) shall be less than 93°. Any angle greater will require fork replacement. The fork manufacturer or service technician with the expertise of equal competence is the only parties that should attempt to make such repairs.

93° Max Figure 21297

Fatigue A fatigue crack will normally start in the heel area of the fork. Cracks can usually be detected in the early stages by inspection of the heel area. Check for cracks that transverse the fork in an area up to 130 mm (5.0 in) either side of the inner heel radius. These cracks are a sign that the area has weakened and the fork needs to be replaced. A visual inspection for cracks should be made each work day. If a more accurate inspection is necessary, dye penetrates can be used or magnaflux the forks.

Figure 21300

To check the fork, a carpenters square can be used, refer to Figure 21301. Hold the square against the shank staying above the radius of the heel as shown. Measure the distance closest to the radius of the heel of the fork blade and square. Add 31.8 mm (1.25 in) to this measurement and record. If the distance between the end of the square and blade is greater than this calculation, replace blade as the fork is deformed more than 93°.

Figure 21299 Crown 2005 PF15092-4 Rev. 1/10

TSP 6000 Series

M7.8-1960-004 02 Rev. 1/10

463

LIFTING MECHANISM Fork Inspection

Figure 21301

Hanger Check for cracks or damage in the area of fork attachment. Check carriage and fork rod for excessive wear or cracks. Repair or replace parts if necessary.

WARNING If the fork locking pin is not fully engaged, the fork could become unintentionally disengaged. Check condition of fork locking pin, spring, etc. for proper operation. Check for adequate lubrication of fork rod and locking pin.

Figure 21302

M7.8-1960-005 02 Rev. 1/10

464

TSP 6000 Series

Crown 2005 PF15092-5 Rev. 1/10

CYLINDERS

465

Notes:

466

CYLINDERS TF Lift Cylinders

TF Lift Cylinders

CAUTION

Great care and cleanliness should be exercised in the disassembly and assembly of hydraulic cylinders. Wipe all surfaces clean of dirt and oil before attempting disassembly. Care should be taken when removing the ram from the cylinder to prevent damage to the packing on the piston end. After cylinder components are disassembled and seals, o-rings and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with low pressure air. Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted or worn. Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool. Place washed components in a clean container until reassembly. Whenever new packings are required, new wiper rings should also be installed.

Pivoting The Tip-Out Assembly (Accessing the Lift Cylinders)

Do not use blocking that is more than 25 mm (1.0 in) thick. Using thicker blocking may deform and damage the hydraulic tubes located at the top of the mast when lowering the second stage mast. 3. Completely lower the second stage mast onto the steel plates. 4. Disconnect battery and chock load wheels. 5. Remove the cover on the top of the mast. A short chain is attached to the cover to allow it to be moved and hung aside. 6. The primary (free) lift cylinder must be secured prior to removing mounting bolts from the cylinder rams otherwise it will be free to fall into the mast. A hole is located at the top of the pulley plate mounting bracket to allow for chain, cable, etc. to secure the primary (free) lift cylinder. Refer to Figure 21278.

To gain access to the lift cylinders for repair or removal, proceed as follows: Note: The second stage mast must be blocked to allow the mast tip-out assembly to be pivoted. 1. To block the mast, raise the second stage mast so that the column roller covers on the bottom of the mast can be easily removed. 2. Position approximately 250 mm (10 in) square steel plates (1), 13 to 25 mm (0.5 to 1.0 in) thick, on top of the base of the mainframe, against each mainframe I- beam. Refer to Figure 21277.

Figure 21277

Crown 2005 PF15093-1 Rev. 1/09

TSP 6000 Series

M8.0-1960-001 01 Rev. 1/09

467

CYLINDERS TF Lift Cylinders

Figure 21278 1

Primary (Free) Lift Cylinder Assembly

Second Stage Mast

Pulley Bracket with Anchor Access Hole

Mainframe

Figure 21279

7. Using a hoist or other lift truck, raise the platform approximately 0.5 m (2 ft). This procedure will produce slack in the lift chain, cables and hoses. Block the platform securely with 100 mm x 100 mm (4 in x 4 in) hardwood blocks. 8. Remove the one bolt (1) securing the secondary (main) lift cylinder (6) to the tip-out assembly (8). Refer to Figure 21279.

9. Remove the two bolts (2) that secure each primary (free) lift cylinder ram (5) to the tip-out assembly (8). 10. Remove the four tip-out assembly mounting bolts (3). 11. Attach a cable, chain, etc. to the chain anchor mounted on the back of the tip-out assembly and secure. This will prevent the anchor and chain from falling into the mast. 12. Remove one of the retaining rings (4) securing the pin in the chain anchor. This will allow easier removal of the chain anchor later.

M8.0-1960-002 01 Rev. 1/09

468

TSP 6000 Series

Crown 2005 PF15093-2 Rev. 1/09

CYLINDERS TF Lift Cylinders 13. Open the manual lowering valve (refer to Figure 21280) located on the back of the power unit. This will relieve pressure causing the secondary (main) lift cylinder ram (6) to retract.

Manual Lowering Valve

Figure 21281 1

Tip-Out Assembly

Figure 21280

Past Vertical

14. Pull the cables and hoses free of the tip-out assembly, move them to the side, and secure them.

Rod Placement

NOTE

17. For easier access to the primary (free) lift cylinders, remove the tip-out assembly mounting blocks (7) from the second stage mast.

The primary (free) lift cylinder rams have a spacer for each mounting bolt along with a button rest for each ram that must be carefully removed to prevent being dropped into the mast mainframe area when pivoting the tip-out. 15. Pivot the tip-out assembly (8) just enough to pull the pin out of the chain anchor. The chain anchor should fall free from the tip-out and hang from the attached cable, chain, etc. used in step 11. 16. Pivot tip-out assembly past vertical and place a rod between the I-beam and tip-out to prevent the inadvertent return of the tip-out to its operating position. Refer to Figure 21281.

Crown 2005 PF15093-3 Rev. 1/09

TSP 6000 Series

M8.0-1960-003 01 Rev. 1/09

469

CYLINDERS TF Lift Cylinders Primary (Free) Lift Cylinder Repair When an excessive amount of hydraulic oil is evident on the top of the cylinder where the ram exits from the cap, the rod packing is probably bad and should be replaced. The replacement of the packing can be accomplished without removing the ram assembly from the cylinder tube or truck. 1. Make sure all hydraulic pressure has been removed from the lift cylinders.

WARNING Avoid high pressure fluids - Escaping fluids under pressure can penetrate the skin causing serious injury. • Relieve pressure before disconnecting hydraulic lines. • Tighten all connections before applying pressure.

Figure 21282

•

Keep hands and body away from pin holes which eject fluids under high pressure. • Use a piece of cardboard or paper to search for leaks. Do not use your hand. Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately from a specialist who has had experience with this type of injury.

Cap

Cylinder Tube

Bleed Screw

NOTE The seals used in the cylinders are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

2. Carefully remove hydraulic fittings from lift cylinder rams. Attempt to absorb any hydraulic oil draining from lines during this procedure. 3. Remove cylinder cap by turning it in a counterclockwise direction.

M8.0-1960-004 01 Rev. 1/09

470

TSP 6000 Series

Crown 2005 PF15093-4 Rev. 1/09

CYLINDERS TF Lift Cylinders

Figure 21284 Figure 21283 1

Ram

Wiper Ring

Cylinder Cap

Packing

Collar

Cylinder Tube

Screwdriver

No. 8 Metal Screw - Headless (4 mm Self-Tapping)

Weld (grind off excess) to a maximum diameter of 4 mm (0.156 in)

Tape

6. Insert the tools between the ram and the cylinder walls, 180° apart, and screw into the face of the packing (refer to Figure 21285).

Note: The packing is located below the cap and remains in the cylinder bore after the cap is removed. A pair of special tools can be utilized to facilitate packing removal. Refer to Figure 21284. 4. To make these tools, weld or braze a headless No. 8 metal screw to the end of a screwdriver. The screwdriver must have at least 152 mm (6 in) of shank length with no larger than 4 mm (0.156 in) shank diameter. 5. After attaching the screw to the screwdriver, grind off excess weld to a diameter of 4 mm (0.156 in). Wrap the shank with electrical tape from the tip of the screw to the screwdriver handle. This will prevent scratching of the cylinder bore or the ram. Figure 21285 1

Cylinder Tube

Seal Pulling Tool

Ram

Seal

7. After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

Crown 2005 PF15093-5 Rev. 1/09

TSP 6000 Series

M8.0-1960-005 01 Rev. 1/09

471

CYLINDERS TF Lift Cylinders Cylinder Packing Installation

NOTE Extreme care should be taken to prevent damage to cylinder wall and ram assembly. 8. At this time, the wiper ring should also be removed since packings and wiper rings should always be replaced in pairs. 9. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before installing new seals.

CAUTION Close inspection of critical seal seating areas should be made before installing new seal(s). Refer to Figure 21286. Your seal failure may not have been caused by a worn seal, but rather, by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability.

For lip first installation, a sleeve similar to that shown in Figure 21286 should be used to protect the seal from damage on threads and shoulders. (Crown has a packing sleeve available, part number 091240-018.)

CAUTION Seal installation tools should be made of soft metal or suitable plastic, free of burrs and sharp edges. Screwdrivers and other similar tools should not be used as they may damage the sealing edges. 1. After packings, seals, bushings, etc. are in place, install the cap.

CAUTION Care should be taken when inserting the cylinder cap to prevent threads and sharp edges from damaging new seals and packings. 2. Screw the cap clockwise until the cap is tight with the top of the cylinder tube.

Figure 21286 1

Cylinder Tube

Sleeve

Forcing Tool

Seal

Critical Seal Seating Area

Collar

10. Make sure the area in contact with the seal is free of burrs, sharp edges and nicks. 11. Apply light lubrication to the seal and installation groove. Use the same oil that will be used later in the cylinder.

M8.0-1960-006 01 Rev. 1/09

472

TSP 6000 Series

Crown 2005 PF15093-6 Rev. 1/09

CYLINDERS TF Lift Cylinders Reassembling Mast Tip-Out

6. Assemble chain anchor onto tip-out assembly.

1. If the tip-out mounting blocks have been removed from the mainframe, assemble onto mainframe. 2. Position button rests on primary (free) lift cylinder rams and lower the tip-out assembly to its normal operating position. 3. Secure the tip-out assembly onto the mounting blocks. Torque the four 0.625 inch bolts to 108 to 122 Nm (80 to 90 ft Ib). 4. Make sure the button rests are properly positioned on top of the rams and the sleeves are properly positioned in the tip-out. Apply thread locking adhesive (061004-012) to the four M12 bolts and secure primary (free) lift cylinder rams to the tip-out (refer to Figure 21287).

7. Check to be sure chains, hoses and cables are properly routed in the top of the mast. 8. Remove blocks from platform and lower. 9. Connect battery and raise platform just enough to allow the secondary (main) lift cylinder ram to extend into the tip-out assembly. 10. Disconnect battery. Raise and block platform to allow slack in mast chains. 11. Insert the single bolt into the tip-out assembly that secures the secondary (main) lift cylinder ram to the tip-out and tighten. 12. Assemble cover to top of mast. 13. Remove blocks from platform and lower. 14. Raise 2nd stage mast and remove blocks.

NOTE The M12 bolts must not be tightened too excessively so that the sleeves compress.

15. Connect battery and check operation.

Figure 21287 1

Button Rest

Primary (Free) Lift Cylinder Ram

Sleeve

Bar Anchor

M12 Bolts

5. Remove cable, chain etc. securing the primary (free) lift cylinders used when disassembling. Crown 2005 PF15093-7 Rev. 1/09

TSP 6000 Series

M8.0-1960-007 01 Rev. 1/09

473

CYLINDERS TF Lift Cylinders Primary (Free) Lift Cylinder Removal To gain access to the primary (free) lift cylinders, refer to Pivoting The Tip-Out Assembly previously explained in this section. After following those procedures: 1. Disconnect the mast chains from the chain anchor and remove them from the yoke at the top of the primary (free) lift cylinders.

7. Raise the cylinder carefully. 8. The take-up cable must be removed from pulley near the bottom of the cylinder. The rollers at the bottom of the cylinder will align themselves with a notch in the mainframe I-beam; push the cylinder assembly away and out of the mainframe at this point. Refer to Figure 21278.

1. Lay the chains over the top of the tip-out assembly and secure. 2. Disconnect the hydraulic lines from each primary (free) lift ram. 3. Remove stop blocks (1) to cross brace at top of mainframe (3). A 0.250 - 20 tapped hole in the top of the stop block (1) can be utilized as an aid when removing and/or installing to top of mainframe. Refer to Figure 21288. 4. Inserting a screw (2) of appropriate length can be used to hold the block in position while removing or installing to cross brace and reduce the risk of dropping block(s) down into mainframe (3).

Figure 21278

Figure 21288

5. Attach a sling, chain, etc. under the yoke, connect to hoist and apply just enough tension to keep the cylinders in place. 6. Remove the cable, chain, etc. securing the primary (free) lift cylinders used when disassembling the tip-out. M8.0-1960-008 01 Rev. 1/09

474

Primary (Free) Lift Cylinder Assembly

Second Stage Mast

Pulley Bracket with Anchor Access Hole

Mainframe

9. Move the cylinder assembly to a clean work area if further repair is necessary.

TSP 6000 Series

Crown 2005 PF15093-8 Rev. 1/09

CYLINDERS TF Lift Cylinders Secondary (Main) Lift Cylinder Removal To gain access to the secondary (main) lift cylinder, refer to Pivoting The Tip-Out Assembly previously explained in this section. After following those procedures: 1. Disconnect the mast chains from the chain anchor and remove them from the yoke at the top of the primary (free) lift cylinders. 1. Lay the chains over the top of the tip-out assembly and secure. 2. Disconnect the hydraulic lines from the secondary (main) lift cylinder ram. 3. Connect hoist to secondary (main) lift cylinder with chain or sling looped about the bar (used for stabilization) welded to the top of the cylinder tube. Refer to Figure 21289.

Figure 21290 1

Screw

Spacer

Locating Pin

Lockwasher

5. Remove the two bolts securing the bottom of the cylinder to the mainframe. 6. Raise the cylinder assembly until it is clear of the mast assembly.

NOTE Make the hoist connection as close to the top of the cylinder assembly as possible. Reduce the amount of wasted vertical distance as possible. The height of the mast and height of the cylinder assembly may be such that the hoist's connection must be as short as possible. Lifting Rings

7. Move cylinder assembly to a clean work area if further disassembly is required. Figure 21289

4. Move to the base of the mainframe and disconnect hydraulic line at the bottom of cylinder. Take necessary steps to catch the oil that will drain from the cylinder.

Crown 2005 PF15093-9 Rev. 1/09

TSP 6000 Series

M8.0-1960-009 01 Rev. 1/09

475

CYLINDERS TF Lift Cylinders Primary (Free) Lift Cylinder Installation

are fitted to stabilizers welded at the top of the mainframe.

1. Carefully move the cylinder over the mainframe utilizing a hoist with proper chain or sling connected to the top of the cylinder, below the yoke assembly. 2. Lower the cylinder slowly until the rollers at the bottom of cylinder can be positioned onto the mainframe I-beam flange. Continue to lower cylinder assembly making sure the hose take-up cable, poly stops, etc. are properly assembled to cylinder. 3. Assemble stop blocks and connect hydraulic lines. Note: For further procedures refer to Reassembling Mast Tip-Out and Lift Cylinder Bleeding located in this section.

Secondary (Main) Lift Cylinder Installation 1. Carefully move the cylinder over the mainframe utilizing a hoist with proper chain or sling connected to the top of the cylinder tube. A stabilizer bar with loops welded near the top of the tube can make for a suitable pick-up point. Use extreme care when making secure hook up. 1. Position the cylinder assembly in such a manner that the mounting flange at the base of cylinder is toward the tip-out. Refer to Figure 21291.

Mounting Flange should face Tip-Out Assembly

Stabilizers welded to inside front of mainframe

Figure 21292

3. Move to the bottom of the cylinder and install spacers, lockwashers and screws that secure cylinder to the base of the mainframe. Connect hydraulic lines to lift cylinders. Note: For further procedures refer to Reassembling Mast Tip-Out and Lift Cylinder Bleeding located in this section.

Figure 21291

2. Lower cylinder carefully into mainframe. Near the top of cylinder is a stabilizer bar. Holes in this bar

M8.0-1960-010 01 Rev. 1/09

476

TSP 6000 Series

Crown 2005 PF15093-10 Rev. 1/09

CYLINDERS TF Lift Cylinders Lift Cylinder Bleeding After the cylinder is installed in the truck air must be bled from the hydraulic system.Without a load on the forks, pressurize the cylinders. Do not raise the operator compartment through the extension of the lift cylinders. With the operator compartment lowered completely, check the hydraulic fluid and add fluid if necessary.

Occasionally, a slight creep of the fork assembly may occur. This may be due to internal leakage in the piston pack, but it can also be caused by leakage in the solenoid or check valve. To seat these valves properly when this occurs, raise and lower the platform to flush out any foreign material from the valve seat. A thorough check of the system for leaks should be conducted if abnormal oil losses occur.

Any air that may be trapped in the system will be forced to the top of the cylinder(s). When bleeding the main lift cylinder, an access hole is in the second stage and mainframe. The bleed screw can be loosened with a blade screwdriver until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil. Access for the purpose of bleeding the two primary (free) lift cylinders must be done from the top of the mast assembly. Loosen the small bleed screw located at the top of the cylinder(s) until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil.

Figure 21293 1

Primary (Free) Lift Cylinders

Bleed Screw

Mainframe

Second Stage Mast

Access Holes

Blade Screwdriver

Secondary (Main) Lift Cylinders

Crown 2005 PF15093-11 Rev. 1/09

TSP 6000 Series

M8.0-1960-011 01 Rev. 1/09

477

CYLINDERS TN Lift Cylinder

TN Lift Cylinder

8. Remove chain anchor pin (2). Access holes in the mainframe and second stage mast are in line with pin.

CAUTION

9. Hang chain out over edge of mast and secure it.

Great care and cleanliness should be exercised in the disassembly and assembly of hydraulic cylinders. • Wipe all surfaces clean of dirt and oil before attempting disassembly. • Care should be taken when removing the ram from the cylinder to prevent damage to the packing on the piston end. • After cylinder components are disassembled and seals, o-rings and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with low pressure air. • Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted or worn. • Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool. • Place washed components in a clean container until reassembly. • Whenever new packings are required, new wiper rings should also be installed.

10. Remove bolt (4) that secures lift cylinder (5) to tipout assembly (7).

Pivoting the Tip-Out Assembly (Accessing the Lift Cylinder) Refer to Figure 21324. To gain access to the lift cylinder for repair or removal, proceed as follows: 1. Raise the platform approximately 0.5 m (2 ft). 2. Block the platform securely with 100 mm x 100 mm (4 in x 4 in) hardwood blocks. 3. Then lower the cylinder completely. This procedure will produce slack in the lift chain, cables and hoses. 4. Disconnect battery and chock load wheels. Part of Mainframe

5. Secure lift chains to top of platform so all slack is above platform. 6. Remove the cover on the top of the mast. A short chain is attached to the cover to allow it to be moved and hung aside. 7. Remove retaining rings (1) from chain anchor pin (2).

M8.0-1960-100 01 Rev. 1/09

478

Figure 21324

11. Attach a hoist, other lift truck, etc., to the lifting bar (6) on the tip-out assembly (7) and lift so that the cylinder pulls out of the tip-out assembly.

TSP 6000 Series

Crown 2005 PF15097-1 Rev. 1/09

CYLINDERS TN Lift Cylinder 12. Position approximately 250 mm (10 in) square steel plates, 13 to 25 mm (0.5 to 1.0 in) thick, on top of the base of the mainframe, against each mainframe I-beam (refer to Figure 21277). Use a sufficient number of plates to keep cylinder (5) from contacting tip-out assembly (7).

CAUTION Do not use blocking that is more than 25 mm (1.0 in) thick.

Figure 21281

Figure 21277

13. Completely lower the second stage mast onto the steel plates.

Tip-Out Assembly

Past vertical

Rod placement

15. Open the manual lowering valve (refer to Figure 21280) located on the back of the power unit. This will relieve pressure causing the lift cylinder ram (5) to retract.

14. Remove tip-out bolts (8). Pivot the tip-out and place a rod between the tip-out and I-beam to prevent the inadvertent return of the tip-out to its operating position. Refer to Figure 21281.

Manual Lowering Valve

Figure 21280

Crown 2005 PF15097-2 Rev. 1/09

TSP 6000 Series

M8.0-1960-101 01 Rev. 1/09

479

CYLINDERS TN Lift Cylinder Lift Cylinder Repair When an excessive amount of hydraulic oil is evident on the top of the cylinder where the ram exits from the cap, the rod packing is probably bad and should be replaced. The replacement of the packing can be accomplished without removing the ram assembly from the cylinder tube or truck. 1. Make sure all hydraulic pressure has been removed from the lift cylinder.

•

Keep hands and body away from pin holes which eject fluids under high pressure. • Use a piece of cardboard or paper to search for leaks. Do not use your hand. Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately from a specialist who has had experience with this type of injury.

Figure 21283 1

Ram

Packing

Wiper Ring

Collar

Cylinder Cap

Cylinder Tube

Note: The packing is located below the cap and remains in the cylinder bore after the cap is removed. A pair of special tools can be utilized to facilitate packing removal. Refer to Figure 21284.

2. Carefully remove hydraulic fittings from lift cylinder ram. Attempt to absorb any hydraulic oil draining from lines during this procedure. 3. Remove cylinder cap by turning it in a counterclockwise direction.

NOTE The seals used in the cylinder are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

Figure 21284 1

Screwdriver

No. 8 Metal Screw - Headless (4 mm Self-Tapping)

Weld (grind off excess) to a maximum diameter of 4 mm (0.156 in)

Tape

4. To make these tools, weld or braze a headless No. 8 metal screw to the end of a screwdriver. The screwdriver must have at least 152 mm (6 in) of shank length with no larger than 4 mm (0.156 in) shank diameter. 5. After attaching the screw to the screwdriver, grind off excess weld to a diameter of 4 mm (0.156 in).

M8.0-1960-102 01 Rev. 1/09

480

TSP 6000 Series

Crown 2005 PF15097-3 Rev. 1/09

CYLINDERS TN Lift Cylinder Wrap the shank with electrical tape from the tip of the screw to the screwdriver handle. This will prevent scratching of the cylinder bore or the ram.

on the seal seating area, causing the seal to deform and lose its sealing ability.

6. Insert the tools between the ram and the cylinder walls, 180° apart, and screw into the face of the packing. Refer to Figure 21285.

Figure 21286

Figure 21285 1

Cylinder Tube

Seal Pulling Tool

Ram

Seal

Cylinder Tube

Seal

Sleeve

Critical Seal Seating Area

Forcing Tool

Collar

10. Make sure the area in contact with the seal is free of burrs, sharp edges and nicks.

7. After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

11. Apply light lubrication to the seal and installation groove. Use the same oil that will be used later in the cylinder.

CAUTION Close inspection of critical seal seating areas should be made before installing new seal(s). (Refer to Figure 21286.) Your seal failure may not have been caused by a worn seal, but rather, by burrs, nicks and dirt located

Crown 2005 PF15097-4 Rev. 1/09

TSP 6000 Series

M8.0-1960-103 01 Rev. 1/09

481

CYLINDERS TN Lift Cylinder Cylinder Packing Installation

Reassembling Mast Tip-Out

Refer to Figure 21324. 1. If the tip-out mounting blocks have been removed from the mainframe, assemble onto mainframe.

Part of Mainframe

Figure 21324

2. Remove rod from between tip-out and I-beam. 3. Pivot tip-out onto top of mast. 4. Secure the tip-out assembly (7) onto the mounting blocks (9). Torque the four 0.625 inch bolts (8) to 108 to 122 Nm (80 to 90 ft Ib).

M8.0-1960-104 01 Rev. 1/09

482

TSP 6000 Series

Crown 2005 PF15097-5 Rev. 1/09

CYLINDERS TN Lift Cylinder 5. Attach lifting device to tip-out assembly (7). Then raise and remove blocks under second stage mast. 6. Lower to couple lift cylinder (5) and tip-out assembly (7).

2. Move to the base of the mainframe and disconnect hydraulic line at the bottom of cylinder. Take necessary steps to catch the oil that will drain from the cylinder.

7. Insert the single bolt (4) and lockwasher that secures the lift cylinder (5) to the tip-out assembly (7). 8. Align holes of chain anchor (3) and mounting blocks (9) and install chain anchor pin (2). Use the access holes in the mainframe and second stage mast. 9. Remove hardware used to secure chains to top of platform. 10. Connect battery and raise to permit removal of blocks under platform. Lower the platform. 11. Bleed air from lift cylinder, if necessary, as described in Lift Cylinder Bleeding at the end of this section. 12. Install cover on top of mast.

Lift Cylinder Removal To gain access to the lift cylinder, refer to Pivoting The Tip-Out Assembly previously explained in this section. After following those procedures: 1. Connect hoist to lift cylinder with chain or sling looped through lifting rings welded at the top of the cylinder tube. Refer to Figure 21289.

•

Keep hands and body away from pin holes which eject fluids under high pressure. • Use a piece of cardboard or paper to search for leaks. Do not use your hand. Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately from a specialist who has had experience with this type of injury. 3. Remove the two bolts securing the bottom of the cylinder to the mainframe. Refer to Figure 21290.

Figure 21290

Figure 21289

Crown 2005 PF15097-6 Rev. 1/09

Screw

Spacer

Locating Pin

Lockwasher

4. Raise the cylinder assembly until it is clear of the mast assembly.

TSP 6000 Series

M8.0-1960-105 01 Rev. 1/09

483

CYLINDERS TN Lift Cylinder NOTE

• •

•

Make the hoist connection as close to the top of the cylinder assembly as possible. Reduce the amount of wasted vertical distance as possible. The height of the mast and height of the cylinder assembly may be such that the hoist's connection must be as short as possible. If overhead clearance is not sufficient to facilitate cylinder removal, the mast may have to be laid down for cylinder removal (refer to Lifting Mechanism).

5. Move the cylinder assembly to a clean work area if further disassembly is required.

Lift Cylinder Installation 1. Carefully move the cylinder over the mainframe utilizing a hoist with proper chain or sling connected to the top of the cylinder tube. Note: A stabilizer bar with loops welded near the top of the tube can make for a suitable pick-up point.

Stabilizers welded to inside front of mainframe

2. Use extreme care when making secure hook up. 3. Position the cylinder assembly in such a manner that the mounting flange at the base of cylinder is toward the tip-out. Refer to Figure 21291.

Mounting Flange Should Face Tip-Out Assembly

Figure 21292

5. Move to the bottom of the cylinder and install spacers, lockwashers and screws that secure cylinder to the base of the mainframe. 6. Connect hydraulic line to lift cylinder. Note: For further procedures refer to Reassembling Mast Tip-Out and Lift Cylinder Bleeding located in this section.

Figure 21291

4. Lower cylinder carefully into mainframe. Near the top of cylinder is a stabilizer bar. Holes in this bar are fitted to stabilizers welded at the top of the mainframe.

M8.0-1960-106 01 Rev. 1/09

484

TSP 6000 Series

Crown 2005 PF15097-7 Rev. 1/09

CYLINDERS TN Lift Cylinder Lift Cylinder Bleeding After the cylinder is installed in the truck air must be bled from the hydraulic system. Without a load on the forks, pressurize the cylinder. Do not raise the operator compartment through the extension of the lift cylinder. With the operator compartment lowered completely, check the hydraulic fluid and add fluid if necessary. Any air that may be trapped in the system will be forced to the top of the cylinder. When bleeding the lift cylinder, an access hole is in the second stage and mainframe. The bleed screw can be loosened with a blade screwdriver until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil.

Figure 21325 1

Lift Cylinder

Access Holes

Mainframe

Blade Screwdriver

Second Stage Mast

Bleed Screw

Crown 2005 PF15097-8 Rev. 1/09

TSP 6000 Series

M8.0-1960-107 01 Rev. 1/09

485

CYLINDERS Auxiliary Lift Cylinder

Auxiliary Lift Cylinder

diately from a specialist who has had experience with this type of injury.

The auxiliary lift cylinder is located in the auxiliary mast. The cylinder is a single-acting, ram-type, cylinder which when pressurized extends and raises the fork carriage accordingly.

CAUTION Great care and cleanliness should be exercised in the disassembly and assembly of hydraulic cylinders. • Wipe all surfaces clean of dirt and oil before attempting disassembly. • Care should be taken when removing the ram from the cylinder to prevent damage to the rod packing. • After cylinder components are disassembled and seals, o-rings and wipers are removed, thoroughly wash all metallic parts in solvent and blow dry with low pressure air. • Carefully inspect the ram assembly and cylinder bore. Replace if scored, grooved, pitted or worn. • Minor damage to the cylinder bore can be removed with the use of a cylindrical honing tool. • Place washed components in a clean container until reassembly. • Whenever new rod packings are required, new wiper rings should also be installed.

Refer to Figure 21326. When an excessive amount of hydraulic oil is evident at the rod end of the auxiliary lift cylinder, the rod packing (3) or wiper ring (1) in the cylinder cap (2) is probably bad and should be replaced. The replacement of the rod packing and wiper ring can be accomplished without removing the cylinder assembly from the auxiliary mast. Follow the procedure outlined below to replace the rod packing and wiper ring. 1. Lower forks completely, chock load wheels, and disconnect the battery. 2. Make sure all hydraulic pressure is removed from the auxiliary lift cylinder. 3. Attach a hoist or other suitable lifting equipment to the fork carriage. Then raise fork carriage 508 to 610 mm (20 to 24 in) and block it in this position using hardwood blocks. Note: By placing fork carriage in this position, sufficient slack is obtained in the lift chain, hydraulic, and electrical lines (running through auxiliary mast) to allow removal of the yoke assembly.

Auxiliary Lift Cylinder Repair WARNING Avoid high pressure fluids - Escaping fluids under pressure can penetrate the skin causing serious injury. • Relieve pressure before disconnecting hydraulic lines. • Tighten all connections before applying pressure.

•

M8.0-1960-200 01 Rev. 1/09

486

TSP 6000 Series

Crown 2005 PF15098-1 Rev. 1/09

CYLINDERS Auxiliary Lift Cylinder

Wiper Ring

Collar

Cylinder Cap

Cylinder Tube

Rod Packing

Ram

Bleed Screw

Bushing

Seal

Retaining Rings

4. Carefully remove yoke assembly from lift cylinder. 5. Remove cylinder cap (2) by turning it in a counterclockwise direction. Note: The rod packing (3) is located below the cylinder cap (2) and remains in the cylinder bore after the cap is removed. A pair of special tools can be utilized to facilitate packing removal. Refer to Figure 21284.

6. To make these tools, weld or braze a headless No. 8 metal screw to the end of a screwdriver. The screwdriver must have at least 152 mm (6 in) of shank length with no larger than 4 mm (0.156 in) shank diameter. 7. After attaching the screw to the screwdriver, grind off excess weld to a diameter of 4 mm (0.156 in.). Wrap the shank with electrical tape from the tip of the screw to the screwdriver handle. This will prevent scratching of the cylinder bore or the ram. 8. Insert the tools between the ram and the cylinder walls, 180° apart, and screw into the face of the packing. Refer to Figure 21285.

Figure 21284 1

Screwdriver

No. 8 Metal Screw - Headless (4 mm Self-Tapping)

Weld (grind off excess) to a maximum diameter of 4 mm (0.156 in)

Tape

Crown 2005 PF15098-2 Rev. 1/09

TSP 6000 Series

M8.0-1960-201 01 Rev. 1/09

487

CYLINDERS Auxiliary Lift Cylinder

Figure 21285 Figure 21286

Cylinder Tube

Seal Pulling Tool

Cylinder Tube

Seal

Ram

Sleeve

Critical Seal Seating Area

Seal

Forging Tool

Collar

9. After the threads are sufficiently secured into the packing, evenly pull on the screwdriver handles until the packing is removed.

NOTE Extreme care should be taken to prevent damage to cylinder wall and ram assembly.

12. Make sure the area in contact with the seal is free of burrs, sharp edges and nicks. 13. Apply light lubrication to the areas of the cylinder cap where the rod packing and wiper ring will seat. Use the same oil that will be used later in the cylinder.

10. Remove wiper ring (1). (Note: Rod packings and wiper rings should always be replaced in pairs.) 11. Thoroughly clean the area where the seals seat. Any burrs, dirt or seal debris must be removed before installing new seals.

CAUTION Close inspection of critical seal seating areas should be made before installing new seals. (Refer to Figure 21286.) Your seal failure may not have been caused by a worn seal, but rather by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability.

M8.0-1960-202 01 Rev. 1/09

488

TSP 6000 Series

Crown 2005 PF15098-3 Rev. 1/09

CYLINDERS Auxiliary Lift Cylinder Rod Packing Installation

Auxiliary Lift Cylinder Bleeding

1. Apply light lubrication to rod packing and wiper ring. Use the same oil that will be used later in the cylinder.

After the cylinder is installed in the truck, air must be bled from the hydraulic system. Without a load on the forks, raise and lower the mast through one complete cycle. Then, with the mast fully lowered, check the hydraulic reservoir and add fluid if necessary.

2. Install wiper ring in cylinder cap.

NOTE The seals used in the cylinder are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage. 3. Install rod packing in cylinder cap. For lip first installation, a sleeve similar to that shown in Figure 21286 should be used to protect the packing from damage on threads and shoulders. (Crown has a packing sleeve available, part number 091240-004.)

Raise and lower the mast through the complete cycle at least five more times. This action will force any air that may be trapped in the system to the top of the cylinder. Loosen the bleed screw located the top of the cylinder until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil.

CAUTION Care should be taken when installing the cylinder cap to prevent threads and sharp edges from damaging new rod packing and wiper ring. 5. Screw cylinder cap in clockwise direction until cap is tight with the top of the cylinder tube. 6. Install yoke assembly on lift cylinder and replace any components that were previously removed. 7. Attach a hoist or other suitable lifting equipment to the fork carriage. Then raise carriage and remove blocking. 8. Lower forks completely, remove wheel chocks, and connect the battery. 9. Bleed auxiliary lift cylinder (refer to Auxiliary Lift Cylinder Bleeding).

Crown 2005 PF15098-4 Rev. 1/09

TSP 6000 Series

M8.0-1960-203 01 Rev. 1/09

489

CYLINDERS Fork Cylinders

Fork Cylinders

When an excessive amount of hydraulic oil is evident at the rod end of the fork cylinder, the rod packing or wiper ring is probably bad and should be replaced. If the area around the outside of the cylinder has oil present, the o-ring or back-up ring is probably bad and should be replaced. The inability to extend and retract the load indicates the piston seals are bad and the cylinder will have to be disassembled.

The fork cylinders on your truck are double-acting, piston-type, cylinders. Extreme care should be taken when any adjustments or repairs are made to the cylinders. It is important to maintain the relationship of ports and hydraulic lines to prevent problems in reassembly or replacement of parts.

Figure 21328 1

Nut

O-Ring

Rod Packing

Spacer

Piston Rod

Fork Extension

.250 Shoulder Screw

M8.0-1960-300 01 Rev. 1/09

490

Bearing Slide

Clamp Block

Fork

Wiper Ring

Seal

Back-Up

Piston

End Cap

O-Ring

TSP 6000 Series

Crown 2005 PF15101-1 Rev. 1/09

CYLINDERS Fork Cylinders Cylinder Disassembly

•

Refer to Figure 21329. 1. Pivot forks to a straight ahead position. Then raise forks 914 mm (36 in) and block using hardwood blocks. 2. Chock load wheels and disconnect the battery. 3. Make sure all hydraulic pressure is removed from the fork cylinders. 4. Remove the shoulder screw (1) from the tip of the fork extension (2) that connects the fork extension to the piston rod (3).

Keep hands and body away from pin holes which eject fluids under high pressure. • Use a piece of cardboard or paper to search for leaks. Do not use your hand. Any fluid injected into the skin under high pressure should be considered as a serious medical emergency despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately from a specialist who has had experience with this type of injury. 9. Remove screws used to secure block clamps (6) to fork (4) and remove both block clamps.

5. Slide the fork extension (2) off the fork (4) and lay aside.

NOTE Use care when extracting piston rod assembly. Never allow piston rod to come in contact with any sharp edges. 10. Carefully remove piston rod assembly (3) from fork (4). 11. Inspect fork cylinder bore for signs of scoring. Note: If scoring is evident, the fork must be replaced. Hone fork, as necessary, to remove any burrs.

Figure 21329

6. Remove bearings (5) from top and bottom of fork (4). 7. Thoroughly clean rod end area of fork before further disassembly. 8. Disconnect hydraulic lines from rear of fork assembly.

Crown 2005 PF15101-2 Rev. 1/09

TSP 6000 Series

M8.0-1960-301 01 Rev. 1/09

491

CYLINDERS Fork Cylinders Piston Rod Disassembly

Cylinder Reassembly

1. Clamp clevis end of piston rod in a vise. Make certain to clamp near the welded area of the clevis to prevent permanent deformation of clevis.

The seals used in the cylinder are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

2. Remove nut and slide all components off piston rod. 3. Inspect piston rod for scoring. If scoring is evident, the rod must be replaced. 4. Remove back-up ring, o-ring, wiper ring, and rod packing from end cap. Refer to Figure 21328. A hooked tool should like the one shown in Figure 21330 should be used to remove the rod packing.

CAUTION Close inspection of critical seal seating areas should be made before installing new seals. Your seal failure may not have been caused by a worn seal, but rather by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability. 1. Clamp piston in a vise. Wrap the area of the piston that will be clamped in the vise to prevent damaging the finished surface of the piston. 2. Apply light lubrication to o-ring, piston, and piston seal. Use the same oil that will be used later in the cylinder.

CAUTION Figure 21330

Note: Tool should be constructed of aluminum or brass so as not to scratch or nick any surfaces 5. Remove o-ring and seal from piston. Refer to Figure 21328. 6. Inspect all parts paying special attention to seal seating areas. Remove burrs, dirt, and seal debris.

CAUTION

Seal installation tools should be made of soft metal or suitable plastic, free of burrs and sharp edges. Screwdrivers and other similar tools should not be used as they may damage the sealing edges. Cone-shaped installation tools should not be used to install snap-in piston seals as this will cause the seal to be stretched to a much larger diameter which will require very high assembly force. 3. Snap one side of the piston seal into the groove in the piston. Refer to Figure 21331. Then hold the seal with your thumb and snap the seal into the groove. Refer to Figure 12891.

Protect eyes and face when using low pressure compressed air. 7. Wash all metal cylinder components in a good grade solvent and blow dry with low pressure compressed air. Then place parts in a clean area until ready for reassembly.

M8.0-1960-302 01 Rev. 1/09

492

TSP 6000 Series

Crown 2005 PF15101-3 Rev. 1/09

CYLINDERS Fork Cylinders

Critical Seal Seating Area

Figure 21332

Figure 21331 1

Pusher Rod

Critical Seal Seating Area

Groove Alignment Plug

8. Squeeze packing rod together and insert end into bore first. When lower end is engaged in installation groove, release the packing and force upper end downward using pusher rod until packing snaps into place. 9. Make certain packing is installed in groove so that the lips will face the piston when the end cap is installed on the piston rod.

Figure 12891

4. Install o-ring (2) in piston (15) (refer to Figure 21328). 5. Apply light lubrication to o-ring (16), back-up ring (11), wiper ring (10), rod packing (6), and end cap (12). Refer to Figure 21328. Use the same oil that will be used later in the cylinder. 6. Carefully position o-ring (16), back-up ring (11), and wiper ring (10) in end cap (12). 7. Install rod packing (6) in end cap (12). Two tools are required to facilitate the installation: –

–

First, a groove alignment plug (refer to Figure 21332) is needed. It should be flush with the groove edge and any metal or plastic material which is smooth and lubricated may be used. And second, a soft metal or plastic pusher rod.

Crown 2005 PF15101-4 Rev. 1/09

10. Apply light lubrication to the cylindrical portion of piston rod. Use the same oil that will be used later in the cylinder. 11. Install end cap (12), spacer (3), and piston assembly (14, 15) on piston rod (7). Then install nut (1) on piston rod (7) and tighten securely. (Refer to Figure 21328 for proper component location or position.) 12. Carefully guide piston rod assembly into fork (13). Then install clamp blocks to secure end cap (on piston rod) to end of fork. 13. Inspect bearings and replace if necessary. Then install bearings on fork. 14. Install fork extension and secure to piston rod using shoulder screw previously removed. 15. Connect hydraulic lines to rear of fork assembly. 16. Connect battery and run operational checks. Check for hydraulic leaks or malfunction.

TSP 6000 Series

M8.0-1960-303 01 Rev. 1/09

493

CYLINDERS Pivot Cylinders

Pivot Cylinders

Cylinder Removal

Two single-acting, piston-type, pivot cylinders are located in the top of the load handler. As one cylinder becomes pressurized and retracts, the other becomes non-pressurized and is extended. A mechanical linkage between the cylinders pivots the fork carriage and permits smooth pivot action when required.

1. Lower forks completely, chock load wheels and disconnect the battery.

Care and cleanliness should be exercised in the removal and repair of hydraulic cylinders. Wipe all surfaces clean of oil and dirt build-up before attempting cylinder removal from the truck or prior to cylinder disassembly.

4. Disconnect hydraulic lines from cylinders. Catch any oil that may be remaining in the lines.

When an excessive amount of hydraulic oil is evident at the rod end of the pivot cylinder, the rod packing or wiper ring is probably bad and should be replaced. If the area around the outside of the cylinder at the rod end has oil present, the o-ring or back-up ring is probably bad and should be replaced. The inability to extend and retract the load indicates the piston seal is bad and the cylinder will have to be disassembled.

2. Remove cover from top of load handler. 3. Make certain all hydraulic pressure is removed from pivot cylinders.

5. Disconnect chain from end of pivot cylinder piston rods. 6. Remove bolts securing pivot cylinder(s) to load handler. 7. Remove pivot cylinder(s) and move them to a clean, well lighted, work area for further disassembly.

Figure 21333 1

Piston

Wiper Ring

Piston Rod

Cylinder

Wire Retainer

Flatwasher

Rod End

Back-up Ring

Piston Seal

Rod Packing

O-Ring

Nut

M8.0-1960-400 01 Rev. 1/09

494

TSP 6000 Series

Crown 2005 PF15103-1 Rev. 1/09

CYLINDERS Pivot Cylinders Cylinder Disassembly

CAUTION

Refer to Figure 21333. 1. Remove rod end from cylinder. Using an adjustable spanner wrench, carefully rotate rod end to back the wire retainer out of the cylinder tube slot end (refer to Figure 21334). Remove wire retainer and rod end.

Never use a screwdriver to remove seals, as damage and leakage may result.

Figure 21330

4. Inspect all parts while paying special attention to seal seating areas. Remove burrs, dirt, and seal debris.

CAUTION

Figure 21334 1

5. Inspect cylinder for signs of scoring. If scoring is evident, replace cylinder. The cylinder should be honed to remove any burrs that may be present.

Piston Rod

Rod End

Retainer Groove

Wire Retainer

Cylinder

Close inspection of critical seal seating areas should be made before installing new seals. Your seal failure may not have been caused by a worn seal, but rather by burrs, nicks and dirt located on the seal seating area, causing the seal to deform and lose its sealing ability.

6. Inspect piston rod for signs of scoring. If scoring is evident, replace rod.

2. Remove piston rod from cylinder. Use care when removing rod to avoid contact with any sharp edges.

7. Wash all metal cylinder components in a good grade solvent and blow dry with low pressure compressed air. Then place parts in a clean area until ready for reassembly.

NOTE

CAUTION

Do not remove piston from rod unless piston or rod is being replaced. 3. Using a small hooked tool (refer to Figure 21330), remove piston seal from piston. Also remove backup ring, o-ring, rod packing and wiper ring from rod end.

Crown 2005 PF15103-2 Rev. 1/09

Protect eyes and face when using low pressure compressed air.

TSP 6000 Series

M8.0-1960-401 01 Rev. 1/09

495

CYLINDERS Pivot Cylinders Cylinder Reassembly Refer to Figure 21333. The seals used in the pivot cylinders are made of an extremely durable, hard polyurethane material which can be deformed temporarily to allow for installation without permanent damage.

CAUTION

Squeeze packing rod together and insert end into bore first. When lower end is engaged in installation groove, release packing and force upper end downward using pusher rod until packing snaps into place. Make certain packing is installed in groove so that the lips will face the piston when the rod end is installed in the cylinder. 5. Apply light lubrication to the outer diameter of piston, piston seal, rod end, and the inner diameter of rod end and seals. Use the same oil that will be used later in the cylinder.

Make certain critical seal seating areas are free of burrs, nicks, or dirt which could cause the seal to deform and lose its sealing ability. 1. Apply light lubrication to piston and piston seal. Use the same oil that will be used later in the cylinder. Then install seal in piston groove. 2. Apply light lubrication to o-ring, back-up ring, wiper ring, rod packing, and rod end. Use the same oil that will be used later in the cylinder. 3. Carefully position o-ring, back-up ring, and wiper ring in rod end. 4. Install rod packing in rod end. Two tools are required to facilitate the installation. First, a groove alignment plug (refer to Figure 21332) is needed. It should be flush with the groove edge and any metal or plastic material which is smooth and lubricated may be used. And second, a soft metal or plastic pusher rod.

Figure 21332 1

Pusher Rod

Critical Seal Seating Area

Groove Alignment Plug

M8.0-1960-402 01 Rev. 1/09

496

TSP 6000 Series

Crown 2005 PF15103-3 Rev. 1/09

CYLINDERS Pivot Cylinders

Figure 21333 1

Piston

Wiper Ring

Piston Rod

Cylinder

Wire Retainer

Flatwasher

Rod End

Back-up Ring

Piston Seal

Rod Packing

O-Ring

Nut

6. Install piston rod and piston into cylinder. 7. Install rod end and associated seals on piston rod. Push rod end into cylinder until retainer groove in rod end is aligned with slot in cylinder. Refer to Figure 21334. 8. Insert hooked end of wire retainer into hole of rod end and turn rod end with an adjustable spanner wrench until end of wire retainer is flush with cylinder. Avoid turning end of wire retainer too far into the cylinder, thus making removal difficult.

Figure 21334

Crown 2005 PF15103-4 Rev. 1/09

Piston Rod

Wire Retainer

Rod End

Cylinder

Retainer Groove

TSP 6000 Series

M8.0-1960-403 01 Rev. 1/09

497

CYLINDERS Pivot Cylinders Cylinder Installation 1. Install pivot cylinder(s) and secure to load handler using the pins, retainers, and screws that were previously removed. 2. Connect chain to pivot cylinder piston rod ends and make certain fork carriage is synchronized with pivot cylinder position. 3. Connect hydraulic lines to cylinders and tighten connections securely. 4. Connect battery and run operational checks. Check for hydraulic leaks or malfunction. 5. Install cover on top of load handler. 6. Remove load wheels chocks. 7. Bleed pivot cylinders. Refer to Pivot Cylinder Bleeding.

Pivot Cylinder Bleeding After the cylinder is installed in the truck, air must be bled from the hydraulic system. Without a load on the forks, pivot the load handler through one complete cycle. Then, with the mast fully lowered, check the hydraulic reservoir and add fluid if necessary. Pivot the load handler through the complete cycle at least five more times. This action will force any air that may be trapped in the system to the top of the cylinder. Loosen the bleed screw located at the top of the cylinder until all air escapes and only oil continues to flow from the cylinder. Tighten the screw and wipe off all excess oil.

M8.0-1960-404 01 Rev. 1/09

498

TSP 6000 Series

Crown 2005 PF15103-5 Rev. 1/09

PLATFORM

499

Notes:

500

PLATFORM Platform

Platform

•

Left and right brake pedals (BRS1 through BRS4).

•

Left, right and rear operator foot presence pedals (FPS1 through FPS9).

Safe and efficient truck operation is dependent on periodic inspections. When making a routine inspection of the platform, check for the following:

•

Safety belt and tether present and in good condition.

•

Proper gate switch operation (GTSL, GTSR).

Column Roller Area

•

Weakening of gate spring tension.

Inspection and Adjustment

•

Column rollers and thrust rollers that are worn or not turning freely.

Lower Platform Area

•

Column roller plate pivots freely.

•

Bushings, bearings and shafts for wear.

Traverse rack no broken teeth, secure and properly lubricated.

•

Shock absorber pins, brackets, plungers, bumpers and poly stops for wear behind seat.

•

Height sensor reel turns freely behind seat.

•

Control cable extension spring adjustment. Springs should have an overall length of 140 mm (5.5 in) for main mast cable and 152 mm (6.0 in) for auxiliary mast cable. This will give approximately 71 to 80 N (16 to 18 lb) of pull on each cable.

Overhead Guard Area

•

Deformation and cracks.

•

Traverse rack no broken teeth, secure and properly lubricated.

•

Overhead guard cover.

•

Mast shield.

•

Proper location and operation of work lights, dome lights, mirror and fan.

Operator Controls

•

Operator Display Module (ACCESS 1).

•

Steering indicator lights function properly.

•

Switch Panel (KYS, LGS1, LGS2, LGS3 (Opt), ZSS (Opt) and JC.

•

Left armrest controls (APS, ECR1, ECR2, HPSL, POT1, POT2, TBS, TDS, RS and RSS) pivot release button and steering tiller.

•

Right armrest controls (EDS, FS, GUS (Opt), HNS, HPSR, ORS1, PLS, POT3 and PRS) ACCESS 8 and pivot release button.

•

EMS1 switch, traverse override, located under switch panel.

•

Seat moves freely up and down and rotates, only when truck is powered up, (SES, JC318, PC318, SLS and EML) and condition of seat cushions.

Crown 2005 PF15130-1 Rev. 1/09

Figure 21303

•

Hydraulic hoses and control cables for wear and cracks.

•

Hydraulic fittings for leaks.

•

Auxiliary hose and control cables for wear and cracks.

TSP 6000 Series

M9.0-1960-001 01 Rev. 1/09

501

PLATFORM Platform •

Proper adjustment of traverse hose. Traverse hose should be adjusted so there is 6 to 16 mm (0.25 to 0.625 in) clearance between the traverse hose loop and right lower extension.

Lubrication (Refer to Lubrication and Adjustment for lubrication intervals and types of lubricants to use.) Regular lubrication of the platform should include:

•

Traverse hose tray liner for wear.

•

Proper chain slack switch operation (CHS1, CHS2, CHS3, CHS4,).

•

Shaft, bushings and bearings for wear.

•

Proper chain anchor adjustment. Chain anchors should be adjusted so the distance from the platform to the floor measures 460 mm (18.12 in) when platform is completely lowered. Adjust both chain anchors in equal increments to maintain a balanced chain load. Refer to Figure 21304.

•

Application of chain and steel cable lube or equivalent to seat telescoping tubes.

•

A liberal coat of Crown 063002-024 grease or equivalent to column and thrust rollers contact area on the mast.

•

Apply a coating of chain & steel cable lube to the lift chain.

•

Spray a generous amount of solvent (WD-40 or equivalent) on the inside of the height sensor housing to clean, followed with a silicon spray, Lubriplate Spray Lube or equivalent.

•

Application of SAE 40 oil to side gate shafts and bushings and shock absorber pins (can also use Lubriplate Spray Lube).

•

Apply multipurpose grease (063002-024) to upper and lower traverse racks.

Figure 21304

•

Lift chain for cracked plates, tight joints, protruding pins, wear, etc. (refer to Lift Chains for chain maintenance).

M9.0-1960-002 01 Rev. 1/09

502

TSP 6000 Series

Crown 2005 PF15130-2 Rev. 1/09

PLATFORM Platform Mast Shield Refer to Figure 17030-01. To perform maintenance to certain areas of the mast or platform assembly, it may be necessary to remove the mast shield. The mast shield is mounted in rubber molding so it is fully suspended. The molding and safety glass should be assembled as shown in Figure 17030-01. The wedge locking strip must be pressed into the open groove to secure the glass in place. A wedge insertion tool (Crown 103792) will greatly aid in the installation of the wedge locking strips. To use the tool: 1. Feed the strip through the throat of the tool head leaving approximately 25.4 mm (1.0 in) of strip exposed beneath the head. 2. Insert tool into the V slot in the main molding body. 3. Once started, with both the strip and body ends flush, clamp the end with your thumb and push the tool through the slot. If the tool seems to push relatively hard, apply a little heat to the molding. This will liquefy the film which covers the molding and act as a rubber lubricant. Figure 17030-01

Crown 2005 PF15130-3 Rev. 1/09

Main Moulding Body

Wedge Locking Strip

Wedge Insertion Tool

Glass

TSP 6000 Series

M9.0-1960-003 01 Rev. 1/09

503

PLATFORM Platform Gates Located on each side of the platform is a gate that can be rotated up to allow for entry or exit. Truck's lift, lower and traction functions are inhibited if one or both gates are not down. To repair or replace the gate switches, torsion springs, lower pivot shafts, etc., proceed as follows: 1. Raise gate to the up position allowing for the least amount of spring tension.

4. Use a spanner wrench (Crown 104712), refer to Figure 17035-01 that has two 1.5 mm (5/32 in) pins at a spread of 23.8 mm (15/16 in) and position the spanner wrench at the shaft end. Keep the gate up and remove the roll pin securing the lower portion of the gate to the shaft. 5. As the roll pin is removed, the spring tension will be transferred to the spanner wrench. You will have to assume this load with the spanner wrench to remove the punch used to drive the roll pin out.

2. Remove two mounting screws from the cover at the lower arm pivot point. 3. Remove switch assembly from bottom of gate mounting bracket. Spanner Tool

Figure 17035-01

6. Remove all necessary parts noting their location for correct position when assembling. To apply spring tension when assembling, turn the pivot shaft toward the front of platform, toward the load handler, until the roll pin can be installed through the lower portion of the gate and shaft.

Figure 21305 1

Left Platform Gate Shown

Switch and Gate Spring

Use spanner wrench here to remove spring tension

Remove switch mounting screws

M9.0-1960-004 01 Rev. 1/09

504

TSP 6000 Series

Crown 2005 PF15130-4 Rev. 1/09

PLATFORM Platform GTSL & GTSR

Chain Anchor and Platform Height Adjustment

Gate Switches The gate switches supply a signal to whether the gates are open or closed. To access these switches, remove two mounting screws from bottom of gate mounting bracket at the lower arm pivot point. Remove switch assembly out through bottom of bracket. Refer to Figure 21305. The gate switches are wired normally open and are held closed when the gates are down. When either gate is up the switch opens and prevents lift, lower and traction functions. There are no adjustments for these switches. Refer to Figure 21306 for placement and location of components that make up the left and right gate switches.

To balance the chain anchors, block the platform to remove the load from lift the chains so the platform is less than 460 mm (18.12 in) above the floor. Adjust chain anchors incrementally until both spring collars just touch the platform. Incrementally adjust both chain anchors in equal increments to tension chains until platform lifts from blocking. An alternative method to balance the chain anchors or to verify balance is to use a direct readout torque wrench, not click style, and equalize nut torque of the two anchors. The platform lift chain anchors should be adjusted so the distance from the platform to the floor measures 467 mm (18.38 in) when the platform is completely lowered. Adjust chain anchors so an equal amount of tension is placed on each of the lift chains.

Figure 21306 1

GTSL Switch Assembly

Cover

Switch

Insulators

Plate

Crown 2005 PF15130-5 Rev. 1/09

TSP 6000 Series

M9.0-1960-005 01 Rev. 1/09

505

PLATFORM Platform Side Thrust Roller Adjustment - Platform (TF, TN and TT Mast) 1. Insure column rollers are installed with large radius toward stud shoulder and retaining rings are intact. Refer to Figure 21307. When replacing column rollers, clean column roller studs. 2. If any paint or rust is present on studs, remove with emery cloth and lubricate with multi-purpose grease Crown 063002-024 or equivalent.

9. Repeat steps 1 through 8 for the upper set of thrust rollers. 10. Move the platform up and down 2nd stage mast. Check to see if the thrust rollers roll about 75% of the time without heavy marking of the mast. 11. Inspect platform to see if the gaps between the uprights and 2nd stage mast are relatively even. If platform rubs on the 2nd stage mast or does not appear to sit square on mast, readjust side thrust rollers.

Traverse Hose Replacement NOTE Right and left references shall be to the truck relative to the operator facing the forks. 1. To replace the traverse hose, traverse the load handler completely to the right as this will allow for better access and easier disassembly and assembly of the traverse hose connections at the load handler.

NOTE

Figure 21307 1

Large radius towards mounting stud

2nd Stage Mast

Column Roller

No shims

It is recommended the traverse hose be replaced as a pair.

3. Adjust cam shafts to their loosest setting. Apply a light film of grease to both ends of cam shaft if needed. 4. Force the platform to one side of the 2nd stage and push column rollers against stud shoulders.

2. Raise platform 915 to 1525 mm (36 to 60 in) if possible. Place blocks under platform and lower platform onto blocks to relieve hydraulic pressure in the raise and lower circuit. 3. Disconnect battery and chock load wheels. 4. Remove load handler covers.

5. Measure the gap, on both sides, between the column roller face and web of the I-beam. 6. Divide the sum of these two gaps by 2 and place this amount of shim, or gage, between column roller and web on side of platform. Example: Gap = 4.0 mm (0.157 in) + 1.0 mm (0.04 in) ÷ 2 = 2.5 mm (0.10 in) 7. Adjust cam on opposite side of shim or gage so the thrust roller contacts the flange of the I-beam. 8. Remove the shim or gage and adjust the other cam so the thrust roller contacts the flange of the I-beam.

M9.0-1960-006 01 Rev. 1/09

506

•

TSP 6000 Series

Crown 2005 PF15130-6 Rev. 1/09

PLATFORM Platform despite an initial normal appearance of the skin. There is a delayed onset of pain, and serious tissue damage may occur. Medical attention should be sought immediately from a specialist who has had experience with this type of injury. 5. Disconnect hoses at bulkhead under the left side of platform and at the load handler. 6. Note location of connections, cut any cable ties, disconnect hose clamps and remove traverse hose assembly. 7. Inspect hoses and connectors for leaks, worn hoses, missing clamps and hardware. Replace as needed. 8. Mount the bulkhead bracket to have a 6 to 16 mm (0.25 to 0.625 in) gap between the hose and right lower extension with the load handler positioned fully to the right. Refer to Figure 21308. 9. For trucks with a traverse frame 152 mm (5.0 in) wider than the platform width (maximum design traverse frame for platform), the bulkhead bracket should use the hole closest to the center of the truck and another 50.8 mm (2.0 in) to the left. 10. For each 25.4 mm (1.0 in) decrease in traverse frame width from the maximum, position the bracket one hole 12.7 mm (0.50 in) to the left. The bulkhead is slotted to aid adjustment. 11. If the gap between hose and extension cannot be achieved moving bolts one outward is acceptable. 12. Once the correct gap has been achieved between the hose on the lower right extension and load handler torque mounting screws to 25 Nm (18 ft lb). 13. Connect battery and slowly traverse the load handler completely to the left being careful not to damage the hose. 14. Check operation of load handler, recheck traverse hose clearance and check for hydraulic leaks.

Crown 2005 PF15130-7 Rev. 1/09

TSP 6000 Series

M9.0-1960-007 01 Rev. 1/09

507

PLATFORM Platform Platform Removal Note: The weight of the platform, without the load handler, is approximately 900 kg (2000 Ib) and with the load handler is approximately 1450 kg (3200 Ib). Be sure equipment used to lift and support the platform is of sufficient capacity to safely handle this load and overhead clearance is sufficient to remove platform. When removing the platform from 2nd stage mast refer to the following:

1. Raise platform high enough so the thrust roller covers can be removed. 2. Disconnect battery, chock load wheels and securely block platform. 3. Remove the four thrust roller covers from back of the platform and rotate the cam shafts so the thrust rollers will not contact the mast when removing the platform.

Figure 21308 1

Platform

Right Side Lower Extension

Adjust to maintain a 6 - 16 mm (0.25 - 0.625 in) gap between hose and extension with traverse fully to truck right

Hose support weldment in keyhole slot

Bulkhead Bracket

Assemble this bolt to hole nearest to the truck center when traverse frame width is 127 mm (5.0 in) greater than platform width. Assemble one hole 12.7 mm (0.50 in) outward for each 25.4 mm (1.0 in) outward for each 25.4 mm (1.0 in) reduction in traverse frame width. If gap cannot be achieved, moving bolts one hole outward is acceptable.

Slots for final gap adjustment

Hole spacing

Bolt spacing

M9.0-1960-008 01 Rev. 1/09

508

TSP 6000 Series

Crown 2005 PF15130-8 Rev. 1/09

PLATFORM Platform

Figure 21309 Figure 21310

Remove four thrust roller covers

Rotate cam shafts so rollers do not contact the mast during removal

Ferrule crimped to cable to keep from completely winding into height sensor

Remove four thrust roller covers

Remove HCS cover hold cable securely and loosen cable clamping screw

4. Remove cover from height cable switch (HCS) assembly mounted on base of main frame, refer to Figure 21310. Hold height cable securely and loosen cable clamp screw. Being careful not to damage cable, pull cable through main frame. A ferrule has been crimped on the height sensor cable near the end, this should prevent the cable from being completely reeled into the height sensor housing. Slowly allow the cable to be reeled into the height sensor housing until the ferrule contacts the housing.

Crown 2005 PF15130-9 Rev. 1/09

5. Connect battery, remove blocks from platform and lower platform. 6. Disconnect battery and remove the load handler. Refer to Load Handler Removal in Platform section. 7. Attach sling, chain, etc. to top of platform and raise approximately 305 mm (12 in) to allow slack in the lift chains, hydraulic hoses and electrical cable. If using chain, place wood blocks above and below or on upper spur rack teeth to prevent damage when lifting platform. Refer to Control Of Hazardous Energy Lockout/Tagout for lifting and blocking instructions.

TSP 6000 Series

M9.0-1960-009 01 Rev. 1/09

509

PLATFORM Platform

Figure 21312

Figure 21311 1

Overhead Guard

3 Point Hook-Up

Hardwood Block

9. Remove floor mat and covers behind and below seat, allowing access to hydraulic hose and control cable connections, height sensor, chain anchors, shock absorbers, etc. 10. To prevent damage to the height sensor when removing the platform from the mast, install a bolt with a minimum length of 31.75 mm (1.25 in) (Crown 120962) into the height sensor housing as shown in Figure 21312. This bolt locks the reel in place, insuring the cable does not completely reel into the housing. Remove height sensor mounting bolts, disconnect connector CA310 and remove height sensor from platform.

510

Bolt to secure height sensor reel

Remove height sensor mounting screws

11. Note and mark location of the control cables, disconnect cables and unhook springs from cable grips. 12. TF Mast-Remove shock absorber mounting pins and remove both shock absorbers.

8. Block platform securely.

M9.0-1960-010 01 Rev. 1/09

13. Disconnect lift chains from anchors located in middle of platform floor and pull chains from platform. 14. Note and mark location of hydraulic hoses and disconnect hoses. Be prepared to catch any hydraulic oil spills. 15. Remove two hose retainers located at the top of the mast, refer to Figure 21313.

TSP 6000 Series

Crown 2005 PF15130-10 Rev. 1/09

PLATFORM Platform Platform Assembly 1. Prior to assembling platform to 2nd stage mast, apply a liberal coat of multipurpose grease (Crown 063002-024 grease) to column and thrust roller contact area on the mast. 2. Attach sling, chain etc. to top of platform and carefully lower platform into the mast. As the platform is lowered into the mast, check the running clearance of the column and side thrust rollers at various intervals. Refer to Column Roller Adjustment and Side Thrust Roller Adjustment.

Hose Retainers

3. Block platform approximately 915 mm (36 in) from floor. 4. Assemble the two hose retainers at the top of the mast. Also, be sure hoses, cables and chains are properly routed through mast. 5. Apply thread sealant (Crown 061004-005 sealant) to hydraulic fittings and connect hydraulic hoses.

Figure 21313

6. Connect lift chains to chain anchors approximating the adjustment of the chain anchors. Proper chain anchor adjustment will be made later.

16. Pull cables, chains and hoses free of platform and lay over top of mast out of the way. 17. Slowly raise platform out the top of the mast and move to a clean work area for repair.

NOTE Routing chain through the platform can be made less difficult by attaching a wire to the chain, pushing the wire through the platform first and then pulling the chain in position for assembly to anchors. 7. TF Mast-Assemble shock absorbers. 8. Connect control cables, cable grips and springs. Proper spring extension adjustments will be made after platform blocks are removed and lift chain adjustments have been made. 9. Assemble height sensor to platform, feeding the height sensor cable below the platform. 10. Remove locking bolt from height sensor housing. 11. Remove blocks, lower platform and remove chain, sling, etc. from platform. 12. Assemble shield onto overhead guard. 13. Adjust chain anchors so the distance from the platform to the floor is 467 mm (18.38 in) with an equal amount of tension on each lift chain. 14. Adjust cable grips so there is approximately 140 mm (5.5 in) main mast cable and 152 mm (6.0 in) auxiliary cable of spring extension.

Crown 2005 PF15130-11 Rev. 1/09

TSP 6000 Series

M9.0-1960-011 01 Rev. 1/09

511

PLATFORM Platform 15. Install load handler onto platform. Refer to Load Handler Assembly in Platform section. 16. Connect battery and raise platform high enough to allow connection of height sensor cable. 17. Disconnect battery and securely block platform. 18. Thread height sensor cable through the main frame to switch assembly. Adjust cable so the distance from where the cable enters the top of the main frame to the ferrule, crimped onto the cable, measures 76 mm (3.0 in). Refer to Figure 21314.

Seat Pivot Bearing Assembly Refer to Figure 21315. 1. Remove existing pivot bearing from seat support. 2. Prior to installing tapered roller bearings pack them in multipurpose grease (063002-025). 3. Install seal with the spring loaded lip of seal to the bearing side. 4. Install lockwasher and locknut to pivot shaft. 5. Torque locknut to 170 Nm (125 ft lb) while rotating seat support to its maximum in both directions a minimum of three times. 6. Loosen locknut until it is free. Do Not disturb the bearing settings as adjusted. 7. Torque the locknut to 34 Nm (25 ft lb). Turn the locknut until one slot in the locknut is aligned with a tab on the lockwasher and bend the tab up into the slot.

Secure cable and install cover Figure 21314

19. Secure cable to switch lever and install cover.

NOTE For additional information on the height sensing system refer to Platform section. 20. Reconnect JC and PC310 for height sensor.

Figure 21315

21. Connect battery and check for hydraulic leaks, binding, proper switch operation, etc. 22. Install covers and floor mat.

M9.0-1960-012 01 Rev. 1/09

512

Seat Support

Pivot Shaft

Locknut

Lockwasher

Tapered Roller Bearing

Seal

TSP 6000 Series

Crown 2005 PF15130-12 Rev. 1/09

PLATFORM Platform Seat Rotate Switch Adjustment Refer to Figure 13026. 1. Remove floor mat and cover to gain access to seat switch at base of seat support. 2. Manually release the locking pin and rotate seat support to position shown so the support casting actuator arm will contact the switch lever arm of the seat rotate switch. 3. Loosen screws one and two on seat rotate switch (SPS) so the switch mounting plate can pivot around screw one. 4. Rotate switch mounting plate until the switch lever arm makes contact with the actuator arm and activates the switch. 5. Adjust switch mounting plate a little farther past this point to insure the switch will always be activated in this position.

Figure 21316

6. Make sure switch lever arm does not bottom out against the switch body, as this could damage the lever arm.

7. Tighten screws on switch and mounting plate.

Switch Lever Arm

8. Manually release the locking pin and rotate the seat support around to make sure the switch actuates and works properly.

Seat Support

Actuator Arm

Shield

9. Reinstall covers and floor mat.

Screw Number 1

Seat Position Switch (SPS)

Crown 2005 PF15130-13 Rev. 1/09

Locking Pin

Switch Mounting Plate

Screw Number 2

TSP 6000 Series

M9.0-1960-013 01 Rev. 1/09

513

PLATFORM Platform Seat Coil Cord Installation Refer to Figure 21317. When replacing the seat power cord the cord coils must be oriented as shown. If cord coils are not orientated correctly premature wear on the cord will happen every time the seat is raised/lowered. 1. Raise seat to its highest position. 2. Loosen protective tube mounting screws attached at bottom of tube assembly. 3. Remove existing cord from seat support and platform floor. It will be necessary to remove one cable tie, two clamps and connector to remove cord from truck.

NOTE Note how the cord is positioned with the cable tie and clamps on the seat support before removing. Positioning of the new cord must be the same 4. Route the long straight end of the power cord and the coils up through seat support. 5. Push power cord through protective tube and attach connector. 6. Fasten the lower end of the cord coil to the seat support with a new cable tie. Make sure cord is positioned the same as the original cord. 7. Slide the tube down the cord as far as it will go into the hole A as shown. Make sure cord does not slip down in tube.

Figure 21317

8. Pull the cord and tube together to the top of the hole A. Refer to Figure 21317.

Hole A

Protective Cord Tube

9. Holding the protective tube in the same orientation that it will be mounted to the tube assembly, look inside the hole A to see how the coils are oriented. The coils must be orientated toward the front of the seat support as shown in Figure 21317.

Power Cord

10. Install protective tube to bottom of tube assembly. Install upper clamp.

Install connector after cord is in protective tube

Mounts to underside of tube assembly

Seat Support

Coiled end of power cord will be in seat support

Correct orientation of coiled end of seat power cord

11. Install lower clamp and route the cord in the platform floor the same as original one. 12. Verify seat is fully functional.

M9.0-1960-014 01 Rev. 1/09

514

TSP 6000 Series

Crown 2005 PF15130-14 Rev. 1/09

PLATFORM Platform Seat Up/Down Switch Adjustment Refer to Figure 21318. 1. Remove cover from rear of seat to expose the seat switch (SES). 2. Loosen two screws that hold the switch mounting block and then hand tighten the same screws. 3. Apply enough weight to the seat bottom to get the seat pivot castings to contact the seat support and actuator arm. 4. Rotate the switch mounting block until the switch lever arm makes contact with actuator arm and activates the switch. 5. Adjust the block a little farther past this point to ensure the switch will always be activated in this position.

NOTE

Figure 21318 1

Switch Mounting Block

Mounting Screws

Make sure the switch lever arm does not bottom out against the switch body, as this could damage the lever.

Actuator Arm

6. Once switch has been adjusted tighten the two mounting block screws.

Seat Pivot

Seat Support

Switch Lever Arm

7. Remove weight from the seat and verify the switch deactivates and the lever arm is no longer in contact with the actuator arm. Cycle the seat a few times to verify adjustment is correct. 8. Install cover.

Crown 2005 PF15130-15 Rev. 1/09

TSP 6000 Series

M9.0-1960-015 01 Rev. 1/09

515

PLATFORM Platform Mirror Installation And Adjustment 1. Measure 368 mm (14.5 in) from back edge of overhead guard to edge of mounting clamp and orientated as shown. Refer to Figure 21319.

vide the operator with optimum vision when using the mirror. 4. For mirror placement on mounting shaft for 1220 mm (48 in) platforms refer to Figure 21320.

2. Secure mirror mounting clamp and recheck measurement.

5. Slide mirror onto mounting bracket shaft until mirror clamp aligns with the groove on the shaft.

3. Verify face of mounting bracket is horizontal with the overhead guard. Refer to Figure 21319.

6. Evenly tighten the two mirror clamp screws so the clamp is snug on the shaft, but still can be rotated around the shaft.

Figure 21320

Figure 21319 1

Top view of overhead guard

Tube clamp

This face of the mounting bracket to be horizontal

Front view of overhead guard

Mounting location of mirror on shaft for trucks with a 1219 mm (48 in) platform

Groove in shaft

Mounting Bracket

7. For mirror placement on mounting shaft for 1320, 1473 and 1625 mm (52, 58 and 64 in) platforms refer to Figure 21321. 8. Slide mirror onto mounting bracket shaft until mirror clamp aligns with the groove on the shaft. 9. Evenly tighten the two mirror clamp screws so the clamp is snug on the shaft, but still can be rotated around the shaft.

NOTE The mirror's mounting ball and socket are not centered on the mirror. It is important to mount the mirror as shown depending upon platform size in order to pro-

M9.0-1960-016 01 Rev. 1/09

516

TSP 6000 Series

Crown 2005 PF15130-16 Rev. 1/09

PLATFORM Platform

Figure 21322

Figure 21321 1

Mounting location of mirror on shaft for trucks with a 1320, 1473 & 1625 mm (52, 58 & 64 in) platform

1 2

Mirror Profile

Groove in shaft

Mounting Plate Profile

Mounting Bracket

Bottom view of Figures 21320 and 21321

See Detail A

10. From the bottom, look straight up the center of the mirror mounting shaft. Rotate mirror clamp on the shaft until the profile of the mounting bracket visually aligns with the profile of the mirror clamp as shown in Figure 21322, detail A. Tighten the two mirror clamp screws.

Crown 2005 PF15130-17 Rev. 1/09

Detail A

11. Install and position convex mirror label Objects In The Mirror Are Closer Than They Appear in lower right hand corner of the mirror glass.

TSP 6000 Series

M9.0-1960-017 01 Rev. 1/09

517

PLATFORM Platform Mirror Adjustment Refer to Figure 21323. 1. Sit in seat at operator operating height and lock the seat in the 60 degree rotated position. 2. While looking in the mirror, adjust side A of the mirror until it is in line and parallel to the edge of side B of the platform wall. 3. Side C of the mirror should be adjusted and tilted down far enough to see the rear top power unit cover.

Figure 21323 1

Side A

Side C

Side B

4. Have the mirror adjustment checked by the operator in all other operating positions.

M9.0-1960-018 01 Rev. 1/09

518

TSP 6000 Series

Crown 2005 PF15130-18 Rev. 1/09

PLATFORM Height Sensing System

Height Sensing System

4. Hold cable securely and loosen cable clamping screw. Pull cable from switch assembly through tube in main frame.

WARNING Wear appropriate safety items, such as safety glasses and shoes, whenever performing maintenance work. • To avoid injury, do not place fingers, hands, arms, or feet through mast or position them at pinch points. • Make sure blocking material is strong enough to withstand the weight. • Never work under or around a truck that is not properly blocked. Truck must be in an area with enough clearance to safely raise the platform. Refer to Control of Hazardous Energy, Lockout/Tagout section for proper procedure to secure the platform.

5. A ferrule (2) is crimped on the cable which should keep the cable from being completely wound into cable reel. Slowly allow cable to be reeled into the height sensor until ferrule contacts the housing. Refer to Figure 21340. 6. Remove cover from platform wall under seat. 7. Disconnect connector CA310 which exits the height sensor. 8. Install a 3/16-16 x 1.25 inch bolt (1) into height sensor housing. This locks reel to keep cable from completely winding up into housing. Refer to Figure 21341. 9. Remove height sensor mounting bolts (2) and remove from platform. Refer to Figure 21341.

Height Sensor Assembly Removal To remove height sensor assembly from truck: 1. Raise and block platform to allow room to work at cable anchor assembly on main frame base. 2. Chock wheels and disconnect battery. 3. Remove screw and lift cover (1) from switch (HCS) assembly. Refer to Figure 21340.

Figure 21341

Figure 21340

Crown 2005 PF15122-1 Rev. 1/09

TSP 6000 Series

M9.0-1960-100 01 Rev. 1/09

519

PLATFORM Height Sensing System Height Sensor Assembly Installation

switch arm is pulled back against the roll pin (8), the switch should reset.

To install height sensor assembly into truck:

8. When proper adjustment has been achieved, tighten locknut (9) on set screw (7).

1. Position height sensor in platform and secure in place with mounting screws. Feed cable through opening in bottom of platform.

9. Remove blocking from under platform, remove wheel chocks and connect battery.

2. Connect connector CA310 which exits the height sensor.

10. Lower platform completely.

3. Remove locking bolt from height sensor housing and install cover. 4. Working under the platform, pull the height encoder cable down to main frame base and thread cable through tube to the switch assembly. 5. Adjust cable so distance between ferrule (crimped on cable) and point cable enters tube measures 89 mm (3.5 in). Wrap cable around cable clamp and tighten screw. Refer to Figure 21340. 6. Position cover switch assembly and secure in place. 7. Remove blocking from under platform, remove wheel chocks and connect battery. 8. Lower platform completely.

Height Cable Broken Switch (HCS) Refer to Figure 21342. Replacement of components: 1. Raise and block platform to allow room to work at cable anchor assembly on main frame base. Figure 21342

2. Chock wheels and disconnect battery. 3. Remove screw (1) and lift cover (2) from switch assembly. 4. Remove switch mounting screws (3) and lift switch (4) from assembly. 5. Disconnect wires from switch being replaced and connect to replacement switch. 6. Make certain insulator (5) is in position. Place switch in assembly and secure in place. Note: The switch arm (6) should not be touching the switch housing, however, the switch should be actuated. 7. If adjustment is required pull switch arm back and turn screw (7) to achieve proper adjustment. When

M9.0-1960-101 01 Rev. 1/09

520

TSP 6000 Series

Crown 2005 PF15122-2 Rev. 1/09

PLATFORM Height Sensing System Height Sensor Assembly

Cable Replacement

Encoder (ECR5)

1. Remove existing cable from reel by cutting cable where sleeve attaches cable to reel.

Refer to Figure 21343. 1. The height sensor assembly must first be removed from truck to replace ECR5. 2. Remove cup shaped cover (1). 3. Loosen set screw (2) holding encoder shaft in reel shaft. 4. Pull encoder (3) from reel shaft. 5. Transfer retainer (4) from encoder being replaced to replacement encoder. 6. Insert encoder shaft into reel shaft aligning flat on encoder shaft so set screw (2) will seat against flat. Make certain notch in retainer slips over taper pin (5) while inserting. Tighten set screw. 7. Install cover over encoder.

2. Install one end of replacement cable in hole on cable reel. 3. Attach sleeve (1) and crimp using swagging tool. Refer to Figure 21344. 4. Install cable reel into outer housing. 5. Install bearing block on outer housing. Make sure wires are pointing up. 6. Place height sensor in a vise. 7. Turn cable reel and feed cable onto reel.

NOTE It is easier to wind cable onto reel with cable reel in outer housing. 8. Make sure cable is evenly wound on reel in reel grooves and cable is not cross threaded on reel.

8. Return height sensor assembly to truck.

9. Leave last groove on outside of reel empty.

Figure 21344 Figure 21343

10. Secure cable and install outer housing over cable reel. 11. Lubricate cable and cable reel. 12. Clean and install spacer over cable reel. 13. Lubricate spacer. 14. Mark one of the mounting holes on height sensor as a reference point. Refer to Figure 21345. 15. Clean, lubricate and install cover.

Crown 2005 PF15122-3 Rev. 1/09

TSP 6000 Series

M9.0-1960-102 01 Rev. 1/09

521

PLATFORM Height Sensing System 16. Using mark placed on the cover (1) as a starting point, rotate cover six complete turns clockwise to pre-load spring. Refer to Figure 21345. 17. After spring has been pre-loaded, secure cover with existing screws.

25. Position cover switch assembly and secure in place. 26. Remove blocking from under platform, remove wheel chocks and connect battery. 27. Lower platform completely.

Figure 21346 Figure 21345

18. Install mounting bracket onto height sensor, if removed, using existing bracket and mounting hardware. 19. Return height sensor assembly to truck. 20. Position height sensor in platform and secure in place with mounting screws. Feed cable through opening in bottom of platform. 21. Connect connector CA310 which exits the height sensor. 22. Remove locking bolt from height sensor housing and install cover. 23. Working under the platform, pull the height encoder cable down to main frame base and thread cable through tube (1) to the switch assembly. Refer to Figure 21346. 24. Adjust cable so distance between ferrule (crimped on cable) and point cable enters tube measures 89 mm (3.5 in). Wrap cable around cable clamp and tighten screw (2). Refer to Figure 21346.

M9.0-1960-103 01 Rev. 1/09

522

TSP 6000 Series

Crown 2005 PF15122-4 Rev. 1/09

GLOSSARY

523

Notes:

524

GLOSSARY Glossary

Glossary Components have been listed in chart form to assist the service technician in locating these components on the Electrical Diagrams and Parts Breakdown forms. The chart is in columns: COMPONENT; LOCATION; FUNCTION; DIAGRAM; PARTS BREAKDOWN. The COMPONENT column contains the abbreviation of the component as it appears on the Diagrams in the Maintenance Section. The LOCATION column gives the

general location on the truck such as on platform or in power unit. The FUNCTION column then explains the function or circuit of that device. The DIAGRAM column gives the page number of the diagram on which the component can be found. The callout in parenthesis following the page number corresponds to the grid callouts on that diagram, locating that component. The PARTS BREAKDOWN column includes the parts breakdown page number on which the component is located along with the index number, in parenthesis, if applicable.

CONNECTIONS Location

Function

Diagram

Parts Breakdown

CA101

Platform Distribution Panel

Seat Forward, Seat Lock Switch, Brake Pedal CHS1, 2, 3 and 4

DIA-1961-004 DIA-1961-005

04.8-1960-001

CA102

Platform Distribution Panel

CAN Download Information (Factory Use Only)

DIA-1961-004 DIA-1961-005

04.8-1960-001

CA103

Platform Distribution Panel

PS1, B+, To ODM, VCM, OCM, PS2

DIA-1961-004 DIA-1960-005

04.8-1960-001

CA104

Platform Distribution Panel

+BV To KYS, EDS, BATT Neg DIA-1961-004 To OCM, ODM DIA-1961-005

04.8-1960-001

CA105

Platform Distribution Panel

CAN L/CAN H To ACM

DIA-1960-004 DIA-1960-005

04.8-1960-001

CA106

Platform Distribution Panel

CAN L/CAN H To ODM CAN L/CAN H To VCM

DIA-1961-004 DIA-1961-005

04.8-1960-001

CA107

Platform Distribution Panel

Mast Cable 2

DIA-1961-004 DIA-1961-005

04.8-1960-001

CA108

Platform Distribution Panel

Mast Cable 1

DIA-1961-004 DIA-1961-005

04.8-1960-001

CA201

Power Unit Distribution Panel

CAN L/H To GCM, HCM Platform, SCM, TCM

DIA-1961-006

04.8-1960-001

CA202

Power Unit Distribution Panel

Dropping Resistors Drive/Tow DIA-1961-006 ED Override Resistors

04.8-1960-001

CA203

Power Unit Distribution Panel

Factory Use

DIA-1961-003 DIA-1961-006

04.8-1960-001

CA204

Power Unit Distribution Panel

ED1/ED2, K2 Switch Inputs

DIA-1961-006

04.8-1960-001

CA205

Power Unit Distribution Panel

Switch Inputs

DIA-1961-006

04.8-1960-001

CA206

Power Unit Distribution Panel

Brake, TCM, SCM, HCM, GCM, BRES, Strobe, CTS

DIA-1961-006

04.8-1960-001

CA207

Power Unit Distribution Panel

ED Override RES5

DIA-1961-006

04.8-1960-001

Crown 2005 PF15329-1 Rev. 12/09

TSP 6000 Series

M10-1961-001 01 Rev. 12/09

525

GLOSSARY Glossary CONNECTIONS (Continued) Location

Function

Diagram

Parts Breakdown

CA301

Switch Panel

FAN1, LGT5, LGT7,

DIA-1961-007

04.8-1960-001

CA302

Switch Panel

LGT2, LGT3, SB31

DIA-1961-007

04.8-1960-001

CA303

Switch Panel

LGT4, LGT6, FAN2

DIA-1961-007

04.8-1960-001

CA304

Platform

Operator Display ACCESS 1

DIA-1961-008

04.8-1960-001

CA305

Switch Panel

KYS, LGS1, LGS2, LGS3, FNS, PS1, JC, ZSS

DIA-1961-008

04.8-1960-001

CA306

Switch Panel

Power for Customer Accessories

DIA-1961-008

04.8-1960-001

CA307

Switch Panel

PC Serial Port

DIA-1961-002 DIA-1961-008

04.8-1960-001

CA308

Platform

GTSR, HGTRS1

DIA-1961-009

04.8-1960-001

CA309

Platform

CHS1, CHS2, CHS3, CHS4

DIA-1961-009

04.8-1960-001

CA310

Platform

Main Height Encoder ECR5

DIA-1961-009

04.8-1960-001

CA311

Platform

Vehicle Control Module ACCESS 4

DIA-1961-010

04.8-1960-001

CA312

Platform

Vehicle Control Module ACCESS 4

DIA-1961-010

04.8-1960-001

CA313

Platform

Vehicle Control Module ACCESS 4

DIA-1961-010

04.8-1960-001

CA314

Platform

Vehicle Control Module ACCESS 4

DIA-1961-010

04.8-1960-001

CA315

Platform

GTSL

DIA-1961-011

04.8-1960-001

CA316

Platform

EML, SLS, SPS

DIA-1961-011

04.8-1960-001

CA317

Platform

8 Conductor Cable Under Seat DIA-1961-011

04.8-1960-001

CA318

Platform

8 Conductor Cable Under Seat, SES

DIA-1961-011

04.8-1960-001

CA319

Platform

Right Front Foot Presence FPS7, FPS8, FPS9

DIA-1961-012

04.8-1960-001

CA320

Platform

Left Front Foot Presence FPS4, FPS5, FPS6

DIA-1961-012

04.8-1960-001

CA321

Platform

Left Rear Foot Presence FPS1, FPS2, FPS3

DIA-1961-012

04.8-1960-001

CA322

Platform

Right Brake Pedal BRS1, BRS2

DIA-1961-012

04.8-1960-001

CA323

Platform

Left Brake Pedal BRS3, BRS4

DIA-1961-012

04.8-1960-001

M10-1961-002 01 Rev. 12/09

526

TSP 6000 Series

Crown 2005 PF15329-2 Rev. 12/09

GLOSSARY Glossary CONNECTIONS (Continued) Location

Function

Diagram

Parts Breakdown

CA324

Platform

Platform Strobe Light Power Supply (Optional)

DIA-1961-012

04.8-1960-001

CA325

Platform

Platform Right Strobe Light LGT8 (Optional)

DIA-1961-012

04.8-1960-001

CA326

Platform

Platform Left Strobe Light LGT9 (Optional)

DIA-1961-012

04.8-1960-001

CA401

Power Unit

Traction Control Module ACCESS 3

DIA-1961-013

04.8-1960-001

CA402

Power Unit

Steering Control Module ACCESS 5, CAN L/H

DIA-1961-014

04.8-1960-001

CA403

Power Unit

Steering Control Module ACCESS 5

DIA-1961-014

04.8-1960-001

CA404

Power Unit

BRES, RGSL, RGSR

DIA-1961-014

04.8-1960-001

CA405

Power Unit

Strobe Light LGT1

DIA-1961-015

04.8-1960-001

CA406

Contactor Panel

CS1, ED1, K2, HN, ALM2, Negative Bus

DIA-1961-015

04.8-1960-001

CA407

Power Unit

Traction Brake

DIA-1961-016

04.8-1960-001

CA408

Traction Motor

Traction Feedback Splitter FSB1

DIA-1961-016 DIA-1961-022

04.8-1960-001

CA409

Traction Motor

Traction Feedback Splitter FSB1

DIA-1961-016 DIA-1961-022

04.8-1960-001

CA410

Power Unit

Steering Feedback Encoder ECR6

DIA-1961-016

04.8-1960-001

CA411

Power Unit

Hydraulic Control Module AC- DIA-1961-017 CESS 2, EMS2

04.8-1960-001

CA412

Mainframe

Mast Cable 1

DIA-1961-018

04.8-1960-001

CA413

Mainframe

Mast Cable 2

DIA-1961-018

04.8-1960-001

CA414

Mainframe

Mainframe Manifold Block, HCS, PVML, PVMR, SP1, SVML

DIA-1961-018

04.8-1960-001

CA415

Mainframe

Hydraulic Motor M2, ECR8, TS2

DIA-1961-018

04.8-1960-001

CA416

Power Unit

CTS (TF Mast Only)

DIA-1961-018

04.8-1960-001

CA501

RH Armrest

Operator Control Module DIA-1961-019 GUS, HPSR, TBS, TDS, RSS

04.8-1960-001

CA502

RH Armrest

Operator Control Module POT1, POT2, POT4

DIA-1961-019

04.8-1960-001

CA503

RH Armrest

Operator Control Module Switch Inputs

DIA-1961-019

04.8-1960-001

Crown 2005 PF15329-3 Rev. 12/09

TSP 6000 Series

M10-1961-003 01 Rev. 12/09

527

GLOSSARY Glossary CONNECTIONS (Continued) Location

Function

Diagram

Parts Breakdown

CA504

RH Armrest

Operator Control Module Switch Inputs

DIA-1961-019

04.8-1960-001

CA505

RH Armrest

GUS, HNS, TBS, TDS

DIA-1961-019

04.8-1960-001

CA506

RH Armrest

Hand LED, +BV

DIA-1961-019

04.8-1960-001

CA507

LH Armrest

APS, HPSL, PLS, ORS1, POT3

DIA-1961-020

04.8-1960-001

CA508

LH Armrest

Steer Command Encoders ECR1, ECR2

DIA-1961-020

04.8-1960-001

CA509

LH Armrest

Battery Negative, C/C DR+, ECR1, ECR2

DIA-1961-020

04.8-1960-001

CA601

Power Unit (Optional)

Guidance/EAC Control Module ACCESS 6

DIA-1961-021

04.8-1960-001

CA602

Power Unit (Optional)

Guidance/EAC Control Module ACCESS 6

DIA-1961-021

04.8-1960-001

CA603

Power Unit (Optional)

Steer Wheel Sensor Bar GS1

DIA-1961-021

04.8-1960-001

CA604

Mainframe (Optional)

Load Wheel Sensor Bar GS2

DIA-1961-021

04.8-1960-001

CA605

Mainframe Bumper (Optional)

EAC Distribution Module EAC Sensor B1

DIA-1961-021

04.8-1960-001

CA606

Mainframe Bumper (Optional)

EAC Distribution Module EAC Sensor A1

DIA-1961-021

04.8-1960-001

CA607

Mainframe Bumper (Optional)

EAC Distribution Module Digital/Analog Inputs

DIA-1961-021

04.8-1960-001

CA608

Mainframe Bumper (Optional)

EAC Distribution Module

DIA-1961-021

04.8-1960-001

CA609

Mainframe Bumper (Optional)

EAC Distribution Module EAC Sensor A2

DIA-1961-021

04.8-1960-001

CA610

Mainframe Bumper (Optional)

EAC Distribution Module EAC Sensor B2

DIA-1961-021

04.8-1960-001

CA611

Power Unit

Optional PDS

DIA-1961-022

04.8-1960-001

CA612

Power Unit

Optional PDS

DIA-1961-022

04.8-1960-001

CA613

Power Unit

FSB2 For Optional PDS

DIA-1961-022

04.8-1960-001

CA614

Power Unit

FSB2 For Optional PDS

DIA-1961-022

04.8-1960-001

CA701

Platform

Battery Inputs, CAN H/L

DIA-1961-023

04.8-1960-001

CA702

Platform

Accessory Control Module Aux. Raise/Lower, Traverse

DIA-1961-023

04.8-1960-001

CA703

Platform

Accessory Control Module Aux. Reset, Fork Home

DIA-1961-023

04.8-1960-001

M10-1961-004 01 Rev. 12/09

528

TSP 6000 Series

Crown 2005 PF15329-4 Rev. 12/09

GLOSSARY Glossary CONNECTIONS (Continued) Location

Function

Diagram

Parts Breakdown

CA704

Platform

Accessory Control Module Load Sense, Pivot, Traverse

DIA-1961-023

04.8-1960-001

CA705

Platform

Traverse Position Encoder ECR4

DIA-1961-023

04.8-1960-001

CA706

Platform

Pivot Position Sense POT5

DIA-1961-023

04.8-1960-001

CA707

Platform

Switch Input FHSL, FHSR, HGTRS2

DIA-1961-023

04.8-1960-001

CA708

Platform

Switch Input SVAL

DIA-1961-023

04.8-1960-001

CA710

Platform

Auxiliary Height Sense Encoder ECR3

DIA-1961-023

04.8-1960-001

CA711

Platform

Load Sense Pressure Transducer LS

DIA-1961-023

04.8-1960-001

TB709

Fork Carriage

Connect Point For FHSL, FHSR, HGTRS2

DIA-1961-023

04.8-1960-001 02.4-1960-100 (4)

CA801

Power Unit

CHS5, CHS6, CHS7, CHS8 (TT Mast Only)

DIA-1960-018

04.8-1960-001

Crown 2005 PF15329-5 Rev. 12/09

TSP 6000 Series

M10-1961-005 01 Rev. 12/09

529

Notes:

530

SCHEMATIC DIAGRAMS

531

Notes:

532

SCHEMATIC DIAGRAMS Introduction to Diagram Usage

Introduction to Diagram Usage

•

The truck has been sectioned with one page covering each section. When options affect the wiring in a section, an additional page is added which duplicates wiring that is identical and adds the option wiring. In this way only one page of the truck section is required for the applicable truck configuration.

•

Wiring that is identified by color rather than number will typically be a cable or wires with vendor componentry.

•

Page titles, listed at the beginning of the electrical diagrams, indicate the subsystem or section of truck wiring that is covered by each page.

Schematic •

•

Power up diagram. Illustrates the circuitry involved in getting the truck system to an operating mode (Can Interface, Access 1,2,3, Controller, Contactor, ect.). Circuitry which stands alone and is separate from truck operation is shown in block form with the pictorials detailing the circuitry (e.g. light package, displays, wire guidance, freezer condition).

Pictorials •

Terminal board and connector numbering on the pictorials are in two classes; power unit and platform. Power unit TB's and CA's are even 100's (200, 400, 600 etc.) and platform TB's and CA's are odd 100's (100, 300, 500 etc.). On manup trucks (SP, TS, TSP etc.), odd and even 100's will be present on the wiring diagrams. Man-down trucks, which don't have a platform (stand-up rider, pallet etc.), only even 100's will be present.

•

Wiring starts at a central location (e.g. distribution board) and wiring connection points are numbered with the lowest number odd or even. The next wiring connection point from the distribution board are then numbered with the next group of 100's and so on for each connection point removed from the central location.

•

Terminal board and connector numbering is sequential on each consecutive page. In this way a wiring address giving a connector number or terminal board number will indicate which direction to look in the diagrams for the other end of the wire. When wiring goes to a component and not a terminal board or connector, a reference terminal board is used and is shown with a dashed line box with the reference terminal board number in parenthesis. This terminal board will not appear on the truck and only present as a wiring directory.

•

Input/Output arrows may appear at terminal boards and connectors. These indicate whether what the wire is carrying is incoming or outgoing. This is helpful when tracing the origin of the signal or voltage.

Crown 1991 PF8974-1 Rev. 6/08

TSP 6000 Series

DIA-ITD-001 02 Rev. 6/08

533

SCHEMATIC DIAGRAMS Electrical Diagrams Index Electrical Diagrams Index

This electrical diagram index lists wiring diagrams with the area or component(s) of the truck covered by each diagram. Exceptions indicated are listed below. Title

Page Number

Revision

Platform Schematic

DIA-1961-002

01 - 3/09

Power Unit Schematic

DIA-1961-003

01 - 3/09

Platform Distribution Panel

DIA-1961-004

01 - 3/09

Platform Distribution Panel W/InfoLink

DIA-1961-005

01 - 3/09

Power Unit Distribution Panel

DIA-1961-006

01 - 3/09

Lights And Fans

DIA-1961-007

01 - 3/09

ACCESS 1 Operator Display

DIA-1961-008

01 - 3/09

Platform Chain Switches

DIA-1961-009

01 - 3/09

ACCESS 4 Vehicle Control Module

DIA-1961-010

01 - 3/09

Platform Seat Area

DIA-1961-011

01 - 3/09

Platform Floor Area

DIA-1961-012

01 - 3/09

ACCESS 3 Traction Control Module

DIA-1961-013

01 - 3/09

ACCESS 5 Steering Control Module

DIA-1961-014

01 - 3/09

Contactor Panel

DIA-1961-015

01 - 3/09

Traction Motor, ECR6, ECR7, FSB1 & Brake

DIA-1961-016

01 - 3/09

ACCESS 2 Hydraulic Control Module

DIA-1961-017

01 - 3/09

Hydraulic Motor, ECR8

DIA-1961-018

01 - 3/09

ACCESS 8 Operator Control Module

DIA-1961-019

01 - 3/09

Platform Left Armrest

DIA-1961-020

01 - 3/09

ACCESS 6 Guidance Control Module

DIA-1961-021

01 - 3/09

ECR7, FSB1, FSB2 & PDS

DIA-1961-022

01 - 3/09

ACCESS 7 Accessory Control Module

DIA-1961-023

01 - 3/09

Power Cables

DIA-1961-024

01 - 3/09

Wiring Harnesses

DIA-1961-025

01 - 3/09

DIA-1961-001 01 Rev. 3/09

534

TSP 6000 Series

Crown 2006 PF15327-1 Rev. 3/09

SCHEMATIC DIAGRAMS Platform Schematic Platform Schematic

139419 D sh2

Crown 2006 PF15327-2 Rev. 3/09

TSP 6000 Series

DIA-1961-002 01 Rev. 3/09

535

SCHEMATIC DIAGRAMS Power Unit Schematic Power Unit Schematic

139419 D sh1

DIA-1961-003 01 Rev. 3/09

536

TSP 6000 Series

Crown 2006 PF15327-3 Rev. 3/09

SCHEMATIC DIAGRAMS Platform Distribution Panel Platform Distribution Panel

134492 J sh1

Crown 2006 PF15327-4 Rev. 3/09

TSP 6000 Series

DIA-1961-004 01 Rev. 3/09

537

SCHEMATIC DIAGRAMS Platform Distribution Panel w/InfoLink Platform Distribution Panel w/InfoLink

134492 J sh2

DIA-1961-005 01 Rev. 3/09

538

TSP 6000 Series

Crown 2006 PF15327-5 Rev. 3/09

SCHEMATIC DIAGRAMS Power Unit Distribution Panel Power Unit Distribution Panel

139422 D

Crown 2006 PF15327-6 Rev. 3/09

TSP 6000 Series

DIA-1961-006 01 Rev. 3/09

539

SCHEMATIC DIAGRAMS Lights And Fans Lights And Fans

139420 A

DIA-1961-007 01 Rev. 3/09

540

TSP 6000 Series

Crown 2006 PF15327-7 Rev. 3/09

SCHEMATIC DIAGRAMS ACCESS 1 Operator Display ACCESS 1 Operator Display

139421 B

Crown 2006 PF15327-8 Rev. 3/09

TSP 6000 Series

DIA-1961-008 01 Rev. 3/09

541

SCHEMATIC DIAGRAMS Platform Chain Switches Platform Chain Switches

134495 C

DIA-1961-009 01 Rev. 3/09

542

TSP 6000 Series

Crown 2006 PF15327-9 Rev. 3/09

SCHEMATIC DIAGRAMS ACCESS 4 Vehicle Control Module ACCESS 4 Vehicle Control Module

134496 E

Crown 2006 PF15327-10 Rev. 3/09

TSP 6000 Series

DIA-1961-010 01 Rev. 3/09

543

SCHEMATIC DIAGRAMS Platform Seat Area Platform Seat Area

134497 G

DIA-1961-011 01 Rev. 3/09

544

TSP 6000 Series

Crown 2006 PF15327-11 Rev. 3/09

SCHEMATIC DIAGRAMS Platform Floor Area Platform Floor Area

134498 D

Crown 2006 PF15327-12 Rev. 3/09

TSP 6000 Series

DIA-1961-012 01 Rev. 3/09

545

SCHEMATIC DIAGRAMS ACCESS 3 Traction Control Module ACCESS 3 Traction Control Module

139423 B

DIA-1961-013 01 Rev. 3/09

546

TSP 6000 Series

Crown 2006 PF15327-13 Rev. 3/09

SCHEMATIC DIAGRAMS ACCESS 5 Steering Control Module ACCESS 5 Steering Control Module

139424 C

Crown 2006 PF15327-14 Rev. 3/09

TSP 6000 Series

DIA-1961-014 01 Rev. 3/09

547

SCHEMATIC DIAGRAMS Contactor Panel Contactor Panel

139425 B

DIA-1961-015 01 Rev. 3/09

548

TSP 6000 Series

Crown 2006 PF15327-15 Rev. 3/09

SCHEMATIC DIAGRAMS Traction Motor, ECR6, ECR7, FSB1 & Brake Traction Motor, ECR6, ECR7, FSB1 & Brake

139429 A

Crown 2006 PF15327-16 Rev. 3/09

TSP 6000 Series

DIA-1961-016 01 Rev. 3/09

549

SCHEMATIC DIAGRAMS ACCESS 2 Hydraulic Control Module ACCESS 2 Hydraulic Control Module

134507 G

DIA-1961-017 01 Rev. 3/09

550

TSP 6000 Series

Crown 2006 PF15327-17 Rev. 3/09

SCHEMATIC DIAGRAMS Hydraulic Motor, ECR8 Hydraulic Motor, ECR8

134508 F

Crown 2006 PF15327-18 Rev. 3/09

TSP 6000 Series

DIA-1961-018 01 Rev. 3/09

551

SCHEMATIC DIAGRAMS ACCESS 8 Operator Control Module ACCESS 8 Operator Control Module

134499 F

DIA-1961-019 01 Rev. 3/09

552

TSP 6000 Series

Crown 2006 PF15327-19 Rev. 3/09

SCHEMATIC DIAGRAMS Platform Left Armrest Platform Left Armrest

134500 E

Crown 2006 PF15327-20 Rev. 3/09

TSP 6000 Series

DIA-1961-020 01 Rev. 3/09

553

SCHEMATIC DIAGRAMS ACCESS 6 Guidance Control Module ACCESS 6 Guidance Control Module

139426 A

DIA-1961-021 01 Rev. 3/09

554

TSP 6000 Series

Crown 2006 PF15327-21 Rev. 3/09

SCHEMATIC DIAGRAMS ECR7, FSB1, FSB2 & PDS ECR7, FSB1, FSB2 & PDS

139427 A

Crown 2006 PF15327-22 Rev. 3/09

TSP 6000 Series

DIA-1961-022 01 Rev. 3/09

555

SCHEMATIC DIAGRAMS ACCESS 7 Accessory Control Module ACCESS 7 Accessory Control Module

134501 F

DIA-1961-023 01 Rev. 3/09

556

TSP 6000 Series

Crown 2006 PF15327-23 Rev. 3/09

SCHEMATIC DIAGRAMS Power Cables Power Cables

139428 C

Crown 2006 PF15327-24 Rev. 3/09

TSP 6000 Series

DIA-1961-024 01 Rev. 3/09

557

SCHEMATIC DIAGRAMS Wiring Harnesses Wiring Harnesses

Harness

Components Connected By:

132239

Hydraulic Harness: JC414, HCS, PVI, PVR, SP1, SVL

132264

Seat Harness: PC503, PC504, PC505(EDS), PC506, SEAT SWITCH (SES)

132562-001 Battery Retainer & Rail Guide Harness: JC404, BRES, LRGS, RRGS 132562-002 Rail Guide Harness: JC404, LRGS, RRGS 132562-003 Battery Retainer Harness: JC404, BRES 132716

Chain Slack Switch Harness: JC309, Includes Switches CHS1, CHS2, CHS3 & CHS4

132717

Contactor Panel Harness: PC204, ED, K2

132718

Seat Position Harness: JC316, SLS, SPS, Includes EML Solenoid

132720-001 RH Armrest Harness: Includes RRS 132735-001 LH Armrest Presence Sensor Harness: Includes HPSL 132735-002 RH Armrest Presence Sensor Harness: Includes HPSR 132783

RH Armrest Harness C/C

132898-001 LH Armrest Harness: Includes APS, PLS, PRS, ORS1 133864-002 Wire Hose Gang Harness: PC105, PC701 134217

Auxilliary Mast Harness: PC708, PC710, SVAL

134219

Strobe Harness

134322

Accessory Cable Harness

135141

Fork Plate Harness

136766

*Auxilliary Hydraulic Harness: PC702, PC703, PC704, PC705, PC706,PC707,JC701, JC708, PVAL, PVF1, PVLH, PVP1 & 2, PVT1 & 2& RES3 In The Harness

136767

*Auxilliary Hydraulic Harness (Optional): PC702, PC703, PC704, PC705, PC706, PC707, JC701, JC708, PVAR, PVAL, PVF1, PVLH, PVP1 & 2, PVT1 & 2& RES3 In The Harness

136796

DT/DTM Adaptor Harness: JC409, PC409

137631

Power Unit Harness: PC201 (CAN BUS), PC205, PC206, PC207, PC401(TCM), PC402(SCM), PC404(BRES), PC405(STROBE), PC406, PC408(Splitter Block), PC410, PC411(HCM), PC412, PC413, PC414, JC415, JC403(SCM), JC407(Brake), PC601(GCM), B-BUS, HORN, K2 COIL, ED COIL, PC416(CTS)

137635

Platform Harness: PC101, PC103,PC104,PC106(CAN BUSS),PC304(ACCESS 1), PC305(KYS), PC306(ACC), PC307(RS323), PC309(CHS1, 2,3&4), PC310, PC311(VCM), PC312(VCM), PC313(VCM), PC314(VCM), PC316(EML), JC317(SEAT), JC319, JC320, JC321, JC322(Right Brake), JC323(Left Brake), Dome Lights, Fan, HGTRS, LGTS, RGTS, Spotlights, Worklight, EMS1

138433

Power Unit Harness: PC201 (CAN BUS), PC205, PC206, PC207, PC401(TCM), PC402(SCM), PC404(BRES), PC405(STROBE), PC406, PC408(Splitter Block), PC410, PC411(HCM), PC412, PC413, PC414, JC415, PC416(CTS JC403(SCM), JC407(Brake), PC601(GCM), PC611, PC612, PC613, PC614, B-BUS, Horn, K2 Coil, ED Coil,

138434

*EAC/Guidance Harness (TSP1.0 Trucks): JC602, PC603, PC604, PC607, PC608

138773

*EAC/Guidance Harness (TSP1.0 Trucks): JC602, PC607, PC608

DIA-1961-025 01 Rev. 3/09

558

TSP 6000 Series

Crown 2006 PF15327-25 Rev. 3/09

SCHEMATIC DIAGRAMS Wiring Harnesses 138932

*Guidance Harness: JC602, PC603, PC604

138953

*EAC/Guidance Harness (TSP1.2/1.5 Trucks): JC602, PC603, PC604, PC607, PC608 *Wire harness selection depends on truck configuration.

Crown 2006 PF15327-26 Rev. 3/09

TSP 6000 Series

DIA-1961-026 01 Rev. 3/09

559

SCHEMATIC DIAGRAMS Wiring Harnesses

Notes:

DIA-1961-026 01 Rev. 3/09

560

TSP 6000 Series

HYDRAULIC SCHEMATIC

561

Notes:

562

HYDRAULIC SCHEMATIC Hydraulic Schematic Hydraulic Schematic

Figure 19915 LH Function Movement S1 = Top Coil, S2 = Lower Coil Pivot CW = S1 Energized, R2 Pressurized Pivot CCW = S2 Energized, R1 Pressurized Fork Extend = S1 Energized, F2 Pressurized Fork Retract = S2 Energized, F1 Pressurized Traverse Right = S1 Energized, T1 Pressurized to “A” Motor Port Traverse Left = S2 Energized, T2 Pressurized to “B” Motor Port

Crown 2005 PF13988-1 Rev. 7/08

TN Lift Cylinder 68.1 l/m, 20.7 MPa (18.0 GPM, 3000 psi)

Velocity Fuse

Velocity Fuse Free Lift

TF Lift Cylinder 71.9 l/m, 20.7 MPa (19.0 GPM, 3000 psi)

Velocity Fuse Free Lift

TT Lift Cylinder 71.9 l/m, 16.5 MPa (19.0 GPM, 2400 psi)

Velocity Fuse

Power Unit Manifold Block

Tank Top Filter Assembly 10 Micron 0.69 MPa (100 psi) Working Pressure

Inner Screen 100 Mesh

Hydraulic Reservoir 47.3 liters (12.5 gallons)

Suction Strainer 30 Mesh

RV1 Pre-Set to 24.8 MPa (3600 psi)

Pump 19 cc Standard, 22 cc High Performance

TSP 6000 Series

HYD-1960-001 01 Rev. 7/08

563

HYDRAULIC SCHEMATIC Hydraulic Schematic

Figure 19916 LH Function Movement S1 = Top Coil, S2 = Lower Coil

1 2

Load Sense Pressure Transducer

Pivot CW = S1 Energized, R2 Pressurized

Traverse 9.4 l/m, 16.5 MPa (2.5 GPM, 2400 psi)

CBV1, CBV2 Set to 17.25 MPa (2500 psi)

Fork Extend 9.4 l/m, 9.6 MPa (2.5 GPM, 1400 psi)

Pivot 3.8 l/m, 9.6 MPa (2.5 GPM, 1400 psi)

Load Handler Manifold Block

CBV3, CBV4 Set to 9.6 MPa (1400 psi)

PR1 Set to 16.5 MPa (2400 psi)

Pivot CCW = S2 Energized, R1 Pressurized Fork Extend = S1 Energized, F2 Pressurized Fork Retract = S2 Energized, F1 Pressurized Traverse Right = S1 Energized, T1 Pressurized to “A” Motor Port Traverse Left = S2 Energized, T2 Pressurized to “B” Motor Port

HYD-1960-002 01 Rev. 7/08

564

Auxiliary Hoist 22.7 l/m, 24.1 MPa (6.0 GPM, 3500 psi)

PR2 Set to 9.6 MPa (1400 psi)

Tilting Forks 9.6 MPa (1400 psi)

TSP 6000 Series

Crown 2005 PF13988-2 Rev. 7/08

HYDRAULIC SCHEMATIC Hydraulic Schematic

Figure 19917 LH Function Movement S1 = Top Coil, S2 = Lower Coil

1 2

Load Sense Pressure Transducer

Pivot CW = S1 Energized, R2 Pressurized

Traverse 9.4 l/m, 16.5 MPa (2.5 GPM, 2400 psi)

CBV1, CBV2 Set to 17.25 MPa (2500 psi)

Pivot 3.8 l/m, 9.6 MPa (2.5 GPM, 1400 psi)

Pivot CCW = S2 Energized, R1 Pressurized Tilt Up = S2 Energized, F1 Pressurized Tilt Down = S1 Energized, F2 Pressurized Traverse Right = S1 Energized, T1 Pressurized to “A” Motor Port Traverse Left = S2 Energized, T2 Pressurized to “B” Motor Port

Crown 2005 PF13988-3 Rev. 7/08

Auxiliary Hoist 22.7 l/m, 24.1 MPa (6.0 GPM, 3500 psi)

Load Handler Manifold Block

CBV3, CBV4 Set to 9.6 MPa (1400 psi)

PR1 Set to 16.5 MPa (2400 psi)

PR2 Set to 9.6 MPa (1400 psi)

Tilting Forks 9.6 MPa (1400 psi)

TSP 6000 Series

HYD-1960-003 01 Rev. 7/08

565

Notes:

566