PDF Service Manual Crown TR 3600 Forklift - 2 MB
This service manual provides comprehensive instructions for the maintenance and repair of the Crown TR 3600 series forklift.
It includes detailed information on troubleshooting, hydraulic systems, electrical diagrams, and component overhaul.
This manual is an essential tool for service technicians to ensure repairs are done correctly and efficiently.
Keep your Crown tow tractor in top working condition.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
INTRODUCTION
Introduction
Introduction Service Training
Use this manual to do troubleshooting and mainte- Service training is available for all Crown trucks, mod-
nance procedures on the truck, and for replacement ule systems, wire guidance, hydraulic, and electrical
parts. systems. For more on service training, consult your
Crown dealer or go to "Training" on www.crown.com.
Operator Instructions
Replacement Parts
This manual does not have operator instructions.
There are operator instructions with each truck. These For correct and fast service, when you consult Crown
instructions are for you and your personnel for years of for replacement parts, always give the truck model,
safe operation of your Crown truck. For operator in- data, and serial number.
structions, refer to "Operator Manual TR 4500 Series".
For the newest service manuals, operator manuals,
training, truck capacities, and truck specifications, con-
Operator Training sult your Crown dealer or go to www.crown.com.
This manual contains sections that have maintenance
Crown has operator training that is available through
and replacement parts. The section descriptions are as
your Crown dealer. For more on operator training, go to
follows:
"Training" on www.crown.com.
Service and Parts Pages Chart
Maintenance Replacement Parts
Section Description Section Description
MA Safety 1 Power Unit Parts
M1 Inspection & Lubrication 3 Drive Unit Parts
M1.91 Componentry 4 Electrical Parts
M3 Drive Unit 5 Brake Parts
M4 Electrical 6 Steering Parts
M5 Brake 10 Accessories
M6 Steering 12 Labels and Decals
M10 Glossary
Crown 2012 PF25665-1 ITD-9245-001
17
--- Page 3 ---
SAFETY
Control of Hazardous Energy
Attaching a Tow Device to the Towed Truck Towing Truck Minimum Requirements
• The tow device must attach to the bottom of the • Use the Tow Device Requirements to calculate the
truck skirt. It must supply pull and brake forces to traction force (this traction force must be within the
the towed truck. The tow device must let the towed tow specifications of tow truck).
truck turn without damage to the truck skirt or the
towed truck. Refer to Figure 26808. • The tow truck and the towed truck must be able to
stop if they have to during the tow procedure.
• Attach a tow strap on the tow truck. Consult the
manufacturer for more information.
Towing Operation Instructions
WARNING
Do not lift the towed truck more than 51 mm (2 in) off of
the floor.
• Make sure that the towed truck does not disengage
from the tow truck during the tow procedure. Attach
the towed truck to the tow truck with clamps or
straps.
Lift and tow the truck here
Figure 26808
MA-9245-006 Crown 2012 PF25623-6
8
--- Page 4 ---
INSPECTION AND LUBRICATION
Planned Maintenance
Planned Maintenance
To make sure that your truck continues to move
materials safely and quickly, you must do regular
maintenance on your truck. Planned maintenance
starts with inspection of the truck. Do all the inspections
on the Operators Daily Checklist (shown previously in
this section of the service manual). Next:
• Move the truck to a maintenance area with a level
floor.
• Turn the truck OFF.
• Put chocks against the wheels to prevent the
movement of the truck. Refer to the Control of
Hazardous Energy section of the Crown Service
and Parts Manual.
• Disconnect the battery.
• Lockout/Tagout the truck. Refer to the Control of
Hazardous Energy section of the Crown Service
and Parts Manual.
• Release the capacitance voltage in ACCESS 3. Re-
fer to the Control of Hazardous Energy section for
the correct procedures.
• Blow off the truck with low pressure air.
• Look for unwanted material in or around the truck
components.
• Look for damaged components.
• Look for loose or missing fasteners. Fig. 1 (26814)
• Look for damaged electrical wires or connectors.
Lift trucks operated in standard operating conditions,
should have planned maintenance performed at the CAUTION
intervals that follow: If repair is necessary on the truck, or the truck is not in
• 180 Day / 500 Hour a safe condition:
• 12 Month / 2,000 Hour • Report immediately to the nearest authority.
Lift trucks operated in environments such as those • Do not operate the truck until it is in a safe
below, require the intervals to be adjusted. Consult an condition.
authorized Crown dealer to determine the proper Do not make repairs or adjustments to the truck unless
interval for the environment. you are approved to do them.
• Freezer Note: You must change the lubrication and inspection
• Outdoor intervals to decrease corrosion and wear on parts for
trucks operated in environments with contamination,
• Extremely dusty moisture, or corrosion.
• Corrosive
A planned maintenance inspection report that contains
all of these items is available from Crown. Consult your Component Access
Crown dealer for planned maintenance inspection This section includes covers, panels, and doors that
reports. An example of a planned maintenance you must open or remove when you do maintenance
inspection report follows: on the truck.
Note: The planned maintenance inspection report is
an example and may not be the newest report.
Crown 2012 PF25668 Rev. 4/18 M1.0-9245-001
01 Rev. 4/18
23
--- Page 5 ---
INSPECTION AND LUBRICATION
Planned Maintenance
Fig. 6 (26819)
Crown 2012 PF25668-11 M1.0-9245-011
33
--- Page 6 ---
LUBRICATION & ADJUSTMENT
Quick Adjustment Caster
Quick Adjustment Caster Caster Adjustment
To optimize and maintain the truck’s brake and stability
performance, the caster should be adjusted periodi-
Adjustment cally to account for tire wear and also when tire re-
placement is necessary. Adjusting the casters up or
General Notes down will affect the operating characteristics of the
truck as shown in chart below.
The brake and caster systems are adjusted at the fac-
tory to provide nominal brake and stability performance
for level, smooth, dry, concrete floors and standard tire WARNING
and load conditions. Upon installation, the truck’s brake
and stability performance should be checked to ensure • Increasing caster loading reduces load on the drive
acceptability. It may be necessary to modify the factory tire and therefore reduces braking effectiveness
settings to properly accommodate the particular oper- and traction.
ating conditions. When a vehicle is operating over a va- • Reducing caster loading reduces stability.
riety of floor and load conditions, it may be impractical Drive tire wear or replacement as well as floor condi-
to adjust the brakes and casters to perform optimally tions will effect operating characteristics of the truck,
for all of the different conditions. mainly:
• Braking/Traction
• Stability/Handling
• Steer Effort
Floor conditions in set up area should be consistent
generally with floor conditions in the overall facility. Pe-
riodic caster adjustments may be required to maintain
proper balance of these characteristics and proper op-
eration.
Caster Adjustment Settings
Caster Caster Drive Tire Traction/Brake Stability/Handling Steer
Adjustment Load Load Performance Performance Effort
Up Decreases Increases Increases Decreases Increases
Down Increases Decreases Decreases Increases Decreases
To adjust casters: 5. Using a 12 mm (0.5 in) hex key, rotate set screw
counterclockwise (viewed from fork end of truck)
1. Rotate caster to a power unit first travel direction
for drive tire wear and clockwise for caster wheel
(as shown).
wear.
2. Raise forks completely. Counterclockwise rotation of set screw moves
caster up (toward power unit).
3. Disconnect battery and block drive tire and forks.
Clockwise rotation of set screw moves caster
4. Refer to figures and loosen the adjustment screw down (toward floor).
locknut. Refer to Figure 16712-01 and set indicators as
shown for either rubber or poly drive tire.
NOTE 6. Tighten jam nut.
With new drive tire and caster wheels, the overall 7. Connect battery, remove blocks and check adjust-
lengths of the compression springs are set from the ment.
factory to measure 75 mm (3 in).
Crown 2007 PF15975-1 Rev. 2/08 M1.5-6745-050
01 Rev. 2/08
95
--- Page 8 ---
ELECTRICAL SYSTEM
Electrical System
Switch Symbols
Actuation Description No. of Momentary Fully Maintained
Terminals
DPDT 8
Fig. 63 (34424)
M4.1-0000-005 Crown 2010 PF17948 Rev. 2/20
02 Rev. 2/20
186
--- Page 9 ---
ELECTRICAL
Electrical System
Examples (All Momentary)
With Common (Transfer) Without Common (Double Break)
Wired normally
open, held open
Figure 8119-01 Figure 8120-01
Wired normally
open, held closed Figure 8122
Figure 8123
Wired normally
closed, held open
Figure 8115-01 Figure 8117-01
Wired normally
closed, held closed Figure 8124 Figure 8125
How the Switch is Activated
If it is necesary to include how the switch is mechani-
cally actuated, a note will be added to the drawing (ex-
ample: operator, lever or truck actuated, etc.)
Application
Switch application is conveyed through the abbrevia-
tion (example: HTS = Height Switch 120 in., DTS =
Drive/Tow Switch).
Notes:
• In a schematic, the condition of a circuit is defined
using a note (example: vehicle shown fully low-
ered with no operator on vehicle).
• Positive action switches are marked with the fol-
lowing symbol:
8126-02
M4.1-2720-006 Crown 2000 PF11845-6 Rev. 10/06
03 Rev. 10/06
136
--- Page 10 ---
ELECTRICAL SYSTEM
Access 1 2 3® Menus
Operator Menus
UserCode Edit 0000–9999
Message Mode Timer Stop
Start
Reset
Trip
SOC
Hours
Odometer
Model
EPS
Hour H1 Runtime1=___ ___ hr
H2 Runtime2=___ ___ hr
H3 Odometer=___ ___ mi
H4 Lift= ___ ___ hr
H5 Traction=___ ___ hr
H6 Steering=___ ___ hr
continued on the next page
Figure 26473-01
Crown 2011 PF25581 Rev. 7/20 M4.3-9245-005
01 Rev. 7/20
37
--- Page 11 ---
ELECTRICAL SYSTEM
Access 1 2 3® Menus
continued from page -013
F13 Electric Steering=___ Disable
Enable
F14 Operator Presence Floorboard=___ Disable
Enable
F17 Electrical Power Source F17.1 Type Lead Acid A
Lead Acid B
Fuel Cell
Li-Ion A
F17.2 Level Level 0
Level 1
Level 2
F18 Walk Along Travel F18.1 Direction=___ Both
PUF Only
None
F18.2 Timeout=___ Edit 5–30 s
F19 Park Brake=___ None
PN 5678-05, 17.1 ohms
PN 5678-31, 8.3 ohms
Figure 26482-01
Crown 2011 PF25581 Rev. 7/20 M4.3-9245-015
01 Rev. 7/20
47
--- Page 12 ---
ELECTRICAL SYSTEM
Access 1 2 3® Menus
A2.3.13 STPS = 0/1 (Step Switch) - The A2.3.13 A2.10.7 Max Discharge Current = Shows the max
STPS menu is available if BRES is closed (=1). 0 = the discharge current in A.
switch is open (the step is down), 1 = the switch is
A2.10.8 Total Ah Charge = Shows the total Ah charge.
closed (the step is up).
A2.10.9 Total Cycles = Shows the total cycles.
A2.3.14 MHSS = 0/1 (Momentary High Speed
Switch) - The A2.3.14 MHSS menu is available if the A2.10.10 Performance Scalar = Shows the lift truck
lift truck is equipped with a momentary high speed performance scalar 0–15 (0–95%).
switch. 0 = the switch is open (the switch is not
A2.10.11 EWS Status - 0/1 - 0 = inactive and 1 = active
pressed), 1 = the switch is closed (the switch is
pressed). A2.10.12 Warning Status - 0/1 - 0 = inactive and 1 =
active.
A2.5 Access 5 - The A2.5 Access 5 menu is available
if the F13 Electric Steering menu is set to Enable. The A2.10.13 Full Load - 0/1 - 0 = inactive and 1 = active.
A2.5 Access 5 menu shows the inputs to Access 5.
A2.10.14 Error Status - 0/1 - 0 = inactive and 1 = ac-
A2.5.1 Access 5 Heatsink Temp = ___ °C - Shows tive.
the temperature of Access 5 in °C.
A2.10.15 Heartbeat Status - 0 = in boot up, 4 =
A2.5.2 HMS = 0/1 (Handle Mount Switch) - 0 = the stopped, 5 = operational, 127 = preoperational
switch is open (the steer head is unlocked and lift truck
A3 Outputs - The A3 Outputs menu is available in
travel is disabled), 1 = the switch is closed (the steer
Level 2. The A3 Outputs menu shows the outputs of
head is locked and lift truck travel is accepted).
monitored lift truck components.
A2.5.3 M3 Temperature = ___ °C (Steer Motor) -
A3.1 Access 1 - Shows the outputs from Access 1.
Shows the temperature of M3 in °C.
A3.1.1 ALM1 = On/Off (Operator Alarm) - On = oper-
A2.5.4 POT2 = ___ V (Steer Command Potentiome-
ator alarm is On, Off = operator alarm is Off.
ter 1) - Shows the POT2 voltage.
Note: POT3 maximum left and right voltages are the A3.1.2 BRK2 Command = ___ mA (Handle Brake) -
opposite of POT2. The A3.1.2 BRK2 Command menu is available if the
F13 Electric Steering menu is set to Enable. The A3.1.2
A2.5.5 POT3 = ___ V (Steer Command Potentiome- BRK2 Command menu shows the BRK2 current in mil-
ter 2) - Shows the POT3 voltage. liamperes.
A2.5.6 POT4 (Steer Tire Position Potentiometer) - A3.1.3 Steer Command = ___ Deg - The A3.1.3 Steer
Use the right arrow to go to the A2.5.6.1 ANGLE menu. Command menu is available if the F13 Electric Steer-
A2.5.6.1 Angle = ___ Deg - Shows the degree of the ing menu is set to Enable. The A3.1.3 Steer Command
steer tire position angle. menu shows the degree of the steer command angle.
A2.5.6.2 Voltage = ___ V - Shows the POT4 voltage. A3.3 Access 3™ - Shows the outputs from
Access 3™.
A2.5.7 RPS1 = ___ Deg (Steer Motor Position Sen-
sor) - Shows the angular position of the M3 sensor. A3.3.1 Battery Voltage = ___ V - Shows the current
battery voltage.
A2.10 EPS - Displayed if F17.2 is greater than or equal
to Level 2. A3.3.2 SOC = ___ % - Shows the percentage of re-
maining battery charge.
A2.10.1 Readiness - 0/1 - 0 = not ready, 1 = ready
A3.3.3 BRK1 = On/Off (Parking Brake) - On = BRK1
A2.10.2 Bus Voltage = Shows the bus voltage in V. is On (the parking brake is released), Off = BRK1 is Off
A2.10.3 Bus Current = Shows the bus current in A. (the parking brake is applied).
A2.10.4 Temperature = Shows the temperature of the A3.3.4 L = On/Off (Line Contactor) - On = L is ener-
battery in °C. gized, Off = L is de-energized.
A2.10.5 SOC = Shows the battery state of charge in %. A3.3.5 M1 Amps = ___ A (Traction Motor) - Shows
the M1 current in amperes.
A2.10.6 SOH = Shows the battery state of health in %.
A3.3.7 Speed Command = ___ mph - Shows the
commanded lift truck travel speed in miles per hour.
Crown 2011 PF25581 Rev. 7/20 M4.3-9245-025
01 Rev. 7/20
57
--- Page 13 ---
ELECTRICAL SYSTEM
Access 1 2 3® Menus
U4.3 Hardware Revision Level = ___ Access 1
shows this menu only if the F17.2 Level menu is set to
2.
U4.4 Software Revision Level = ___ Access 1 shows
this menu only if the F17.2 Level menu is set to 2.
U4.5 Protocol Revision Level = ___ Access 1 shows
this menu only if the F17.2 Level menu is set to 2.
U4.6 Energy Capacity = ___ Ah/g Access 1 shows
the value in Ah/g if the F17.1 Type menu is set to FUEL
CELL. Access 1 shows this menu only if the F17.2
LEVEL menu is set to 2.
U4.7 Number of Cells = ___ Shows the number of
cells in the battery. Access 1 shows this menu only if
the F17.2 LEVEL menu is set to 2.
U4.8 Max Charge Current = ___A - Shows the maxi-
mum number of amps for charging. Access 1 shows
this menu only if the F17.2 LEVEL menu is set to 2.
U4.9 Device ID = ___ Access 1 shows this menu only
if the F17.2 LEVEL menu is set to 2.
Crown 2011 PF25581 Rev. 7/20 M4.3-9245-035
01 Rev. 7/20
67
--- Page 15 ---
ELECTRICAL
Control Pod
Make sure that the torsion spring (8) is above the notch
in the control pod (13). Refer to Figure 26545.
2
3
8
13 1
4
Figure 26545
8. Install the shaft (5).
9. Install as many flatwashers (12) between the cam
(11) and the control pod (13) as required. The flat- 3 2
washers remove the lateral movement of the re-
placement components on the shaft (5). Figure 26536
10. Install the right twist grip (2) in the yoke (3) with the
arrows (14) up and near the control pod (13). You
can also install the right twist grip in the yoke with
the arrows up and near the yoke.
11. Align the key on the extension (4) with the right
twist grip (2).
12. Install the extension (4) on the right twist grip (2)
and attach the extension with the roll pins (1).
13. Install these components:
– The insulator (4)
– The covers (3)
– The screws (2).
Refer to Figure 26536.
14. Do the potentiometer adjustments. Refer to Trac-
tion Accelerator Potentiometer (POT1) Adjustment
with ACCESS 1 in this section.
Crown 2012 PF25604-9 M4.5-9245-009
31
--- Page 16 ---
ELECTRICAL SYSTEM
Battery
Charging
Charging requirements will vary depending on use of
truck. Batteries discharged by more than one-third
should be charged daily. If tees than one-third dis-
charge, recharging should be delayed; however, they
should be recharged at least once a week. If usage of
truck makes it necessary, more than one battery should
be available to provide ample power to the unit at all
times.
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.
Some of the basic rules are as follows:
1. Placing battery on charge:
– Park truck at charging station with forks low-
ered and key removed.
– Unplug battery from truck.
– Be sure charger control is in the off position.
– Connect battery to charger and be sure con-
nectors are mated all the way.
– Set timer for specified time. Set for Normal
(Daily Charge, all except one night a week when
the Equalize [Weekend] Charge should be used).
– Check ammeter to be sure it shows charge.
2. Removing battery from charge:
– Be sure the charger is turned off.
– Break the connectors, using both hands with a
straight pulling motion.
– Hang up the charger cable to prevent damage.
(Broken connectors can cause poor connections
and connector failures).
– Make daily battery checks.
– Connect battery to truck. Be sure connectors
are mated all the way.
M4.6-11.0-002 Crown 1978 PF3379-2 Rev. 10/06
01 Rev. 10/06
--- Page 17 ---
ELECTRICAL SYSTEM
Event Codes
– Then proceed to Step 3. the Access 1 module. Resistance at this point
• If: The voltage is 0.7–4.2 V. should be 119–121 Ω.
– Then replace Access 5. • If: Resistance is not 120 Ω.
Step 3: Turn on the tow tractor and check the voltage – Then replace Access 1.
between CA421-4 (+) and CA421-2 (-). • If: Resistance is 120 Ω.
• If: If: The voltage is not 0.7–4.2 V. – Then disconnect Access 5 connector (CA202)
– Then replace BRK2. and check resistance between pins 15 and 23 on
the Access 5 module. Resistance at this point
• If: The voltage is 0.7–4.2 V.
should be 119–121 Ω.
– Then repair the wire between CA202 and CA421.
• If: Resistance is not 120 Ω.
Note: Apply Nyogel 760G (P/N 127189-001) to the – Then replace Access 5.
wire terminals. Secure the wiring harness at CA202 to
• If: Resistance is 120 Ω.
the Access 5 power cables.
– Then check wiring harness for short between
CAN HI and CAN LO, or for open in CAN HI or
CAN LO.
ACCESS 5
SCM • If: If: Short or open is detected.
062007-128 BUTT SPLICE CA202
5906
2 BRK2 DRIVER – Then replace harness.
704
3 +5V (RPS1, POT2, POT3, POT4)
+5V
NEG
504
4 NEG (RPS1, POT2, POT3, POT4) Step 2: Turn on the tow tractor. Check that Access 5
5906
110
7 POT4 WIPER (DU POSITION)
is staying powered by checking for battery positive at
711 710
510 511
8
9
pin CA202-1.
108
10 POT2 STR CMD1
109
11 POT3 STR CMD2 • If: Event still exists.
– Then replace Access 5.
CA420 • If: Event still exists.
710