BRAKE SYSTEM
Brake System
Brake System
There are two sources of drive wheel braking on this
truck, a 3-stage, spring applied, electromagnetically re-
leased, friction disc brake (BRK1) on the traction motor
(M1) armature shaft and dynamic motor braking, typi-
cally called regenerative braking. The truck has addi-
tional braking in an electromagnetically applied, friction
disc brake (BRK2) in the caster wheel.
When the operator makes a brake request, by releas-
ing either of the two left pedals or by applying the cen-
ter pedal, ACCESS 3 determines the amount of brak-
ing force to be applied based on the known truck
weight (includes battery and maximum allowable fork
load) and the maximum allowable speed for the partic-
ular travel direction and fork height. The total braking
effort is shared between the drive tire and the caster
tire (S-Class trucks only) based on the known weight
distribution. The traction tire portion is further split be-
tween the motor regenerative braking and BRK1. The
motor regenerative portion is made as large as practi-
cal in order to reduce wear on BRK1. BRK1 and BRK2
effort can be electronically adjusted through the Perfor-
mance Menu (P6 and P7) in order to address tire slide
for floor condition and application.
Stopping Distance
Verify the actual truck stopping distance as listed in
Chart 1 before making changes. If the truck no longer
meets the required stopping distance, complete the fol-
lowing adjustments prior to programming P6 and P7 in
the ACCESS 123® Menus:
• Articulation Adjustment. Refer to Drive Unit - Disas-
sembly and Assembly section.
• Compare truck weight (F.4) and max load weight
(F3.3) to the data plate. Refer to ACCESS 123
Menus - Features Menus.
• Drive brake torque gap adjustment. Refer to Torque
Gap Adjustment in this section.
• Condition of the drive tire.
Crown 2009 PF17433-1 Rev. 12/11
CAUTION
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 brak-
ing characteristics that are significantly different from
other similar vehicles being used in the facility. An al-
ternative is for the customer to train the operator to re-
duce travel speed and/or allow for longer stopping dis-
tances.
To check stopping distance
(Caster brakes are only used on S-Class Trucks.)
1. Use ACCESS 1 to set the drive brake (P6) and
caster brake (P7) values to the factory default val-
ues of 6 (P6) and 6 (P7). Travel with no load, on a
level, smooth, dry, concrete surface, at maximum
acceleration from zero to top speed in the forks first
direction and apply the brakes. Use A2.3.1.3 in the
ACCESS 1 menu to monitor the truck speed.
2. Verify the stopping distance, from the maximum
speed, is within the distance listed in Chart 1 with
no caster tire slide and with minimal drive tire slide.
3. Use the ACCESS 1 Performance Menus to make
brake adjustments to the drive brake (P6) and the
caster brake (P7) to address tire slide for specific
floor condition and application. These settings may
be reduced if the standard setting results in tire
slide in the application. If the floor conditions will
accommodate a more aggressive braking force,
then the settings may be increased. The adjust-
ments affect the brake force in both travel direc-
tions when the forks are below the free lift height.
M5.0-1457-001
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559
BRAKE SYSTEM
Brake System

Chart 1 - Stopping Distance

Forks First Maximum Speed Maximum Stopping Distance

Model km/h mph
meters feet
(+0.0/-0.1) (+0.0/-0.1)
RR5715-35 10.14 6.3 2.59 8.5
RR5715-40 10.14 6.3 2.59 8.5
RR5725/RM6025 10.94 6.8 2.90 9.5
RR5795/RM6095 11.10 6.9 2.90 9.5
RD5725/RMD6025 10.94 6.8 2.90 9.5
RD5795/RMD6095 11.10 6.9 2.90 9.5

M5.0-1457-002 Crown 2009 PF17433-2 Rev. 12/11

04 Rev. 12/11
560

Drive Brake (BRK1)
Air Gap Adjustment
Refer to Figure 1
The air gap is the distance between the brake armature
(9) and the magnet coil and body (3) with the brakes
applied. As the brake pads (10) and rotor (5) wear nor-
mally, the air gap (4) will increase and should be read-
justed, or parts checked and replaced, when it exceeds
1.0 mm (0.040 in).
Note: If the air gap (4) measures more than 1.0 mm
(0.040 in), the brake may not release properly. If the
brake pad (10) thickness is less than 2.8 mm
(0.110 in), replace the brake pads and rotor (5).
1. Chock the load wheels. Open the power unit doors
to access the brake (BRK1) on top of the traction
motor (1).
Fig. 1 (21880)
Crown 2009 PF17433-3
BRAKE SYSTEM
Brake System
2. Use low pressure air to remove any dirt between
the armature (9) and magnet coil and body (3).
3. If the truck is equipped with an external traction en-
coder (ECR1) on top of the brake assembly, re-
move the encoder to minimize the risk of damage.
4. Loosen the locknut (7) on the motor shaft (6).
5. Turn the hex nut (8) down until the air gap (4) is
0.25 mm (0.010 in) at its tightest location. One
complete turn of the nut changes the gap 1.4 mm
(0.056 in). A 1/6 (60 degree) turn changes the gap
0.235 mm (0.009 in).
6. Torque the locknut (7) to 122 Nm (90 ft lb).
7. Install the encoder, if applicable. Apply blue thread
locking adhesive to the set screw.
8. Remove the wheel chocks and check for proper
operation.
M5.0-1457-003
561
BRAKE SYSTEM
Brake System

Torque Gap Adjustment
Refer to Figure 1
The torque gap (12) is the distance between the torque
adjuster plate (2) and the magnet coil and body (3).
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 varies based on the truck's gross vehicle weight
(GVW). Refer to the truck capacity plate for the truck's
GVW as equipped with maximum battery and capacity
load. Use Chart 2 to determine the correct torque gap.

Chart 2 Torque Gap Adjustment

Torque Gap GVW (capacity load and maximum battery

mm inch kg lb
0.00 0.00 greater than 6960 greater than 15350
0.50 0.02 6645 - 6960 14650 - 15349
1.00 0.04 6330 - 6644 13950 - 14649
1.50 0.06 5990 - 6329 13200 - 13949
2.00 0.08 5670 - 5989 12500 - 13199
2.50 0.10 5350 - 5669 11800 - 12499
3.00 0.12 5010 - 5349 11050 - 11799
3.50 0.14 4695 - 5009 10350 - 11049
4.00 0.16 4375 - 4694 9650 - 10349
4.50 0.18 4035 - 4374 8900-9649
5.00 0.20 less than 4035 less than 8900

M5.0-1457-004 Crown 2009 PF17433-4

562
 BRAKE SYSTEM
Brake System

Brake Assembly
Refer to Figure 2
Before assembling the brake (BRK1), inspect all com-
ponents for wear, grooves, nicks or other damage. If
any abnormal wear or damage appears that may affect
brake operation, replace with new parts. Assemble the
brake as follows:
1. Turn the torque adjuster plate (14) down as far as
possible to reduce spring force.
2. Apply a light coat of multi-purpose grease
(063002-024) to the motor end cap threads and on
top of the torque adjuster plate (14). Be careful not
to contaminate brake pads with grease.
3. Position the magnet coil and body (13) on the mo-
tor so the coil wires (10) for 24 V trucks, or (13) for
36 V trucks, are positioned as shown.
4. Apply blue thread locking adhesive to the three
screws (15) and secure the magnet to motor.
5. Assemble springs (11), inner armature (9) and
outer armature (8) to the magnet body (13). Apply
a light coat of multi-purpose grease (063002-024)
to entire bottom of brake pad plate assembly (5).
Be careful not to contaminate brake pads with
grease.
6. Install the compression spring (7) over the arma-
ture shaft.
7. Slip the rotor (6) on the motor shaft, hub first.
8. Thread the hex nut (4) onto the motor shaft. Turn
the hex nut (4) down until the rotor (6) moves down
and almost touches the brake pads. The air gap
adjustment will be made later.
9. Thread the locknut (3) onto the motor shaft. Add
flatwasher(s) (2) and place retaining ring (1) on
motor shaft.
10. Set torque adjuster gap to its original factory set-
ting. Refer to Torque Gap Adjustment procedures
in this section.
11. Connect the wire harness to the brake assembly.
12. Adjust the air gap. Refer to Air Gap Adjustment
procedures in this section.
13. Check brake operation and stopping distance. Re-
fer to Stopping Distance in this section. Fig. 2 (21881)

Crown 2009 PF17433-5 M5.0-1457-005

563
BRAKE SYSTEM
Brake System

Chart 3 Troubleshooting Brake System

Problem Probable Cause Remedy

Brakes will not release
Brake drag
Brakes grab
Stopping distance too long
Abnormal noise and chatter when
brakes applied
Abnormal braking force for lift height
or brakes applied without request
Air gap greater than 1.0 mm (0.040 in) Adjust Air Gap
Check floorboard switches
Open circuit in brake circuitry or wiring
and all associated wiring
Armature movement restricted by dirt,
Clean with low pressure air
foreign material
Air gap greater than 0.25 mm (0.010 in) Adjust
Replace mounting plates or
Brake pad mounting plate or rotor distorted
rotor
Armature movement restricted by dirt,
Clean with low pressure air
foreign material
Correct stopping distance
Incorrect stopping distance adjustment
(P6 and P7)
Replace mounting plates or
Brake pad mounting plates or rotor distorted
rotor
Adjust (see P6/P7 Section
Incorrect stopping distance adjustment
M4.3)
Brake pad loose or soiled with grease Replace brake pad
Replace mounting plates or
Brake pad mounting plates or rotor distorted
rotor
Brake pads worn out, loose, soiled with
Replace brake pad
grease, foreign material embedded
Rotor thin, cracked or spline worn Replace rotor
Check and repair all switches
Open circuit in brake circuitry or wiring
and associated wiring

M5.0-1457-006 Crown 2009 PF17433-6

564
 BRAKE SYSTEM
Brake System

Caster Brake (BRK2)

The caster brake is applicable to S-Class trucks only.
Refer to Figure 3.
Two electromagnetically applied disc brakes (BRK2)
(10) are located in the caster wheel assembly. Caster
brakes on all models are factory preset and are not me-
chanically adjustable. Refer to Stopping Distance in
this section for detailed instructions on adjusting brak-
ing via ACCESS 1.
WARNING
Do not attempt to remove or install the caster wheels
and brakes if the power unit is not properly blocked.
Risk of serious injury or even death may occur. Refer
to Control of Hazardous Energy - Lifting and Blocking
for detailed instructions.

Fig. 3 (21882)

Crown 2009 PF17433-7 Rev. 12/10 M5.0-1457-007

03 Rev. 12/10
565
BRAKE SYSTEM
Brake System

Caster Wheel and Brake Removal 4. Chock the load wheels and drive tire.
5. Loosen, but do not remove the caster wheel lug
Refer to Figure 3.
bolts.
1. With no load on the forks, move the truck to a se-
6. Refer to Control of Hazardous Energy section. Lift
cure, non-traffic maintenance area with a level
and block the rear of truck approximately 150 mm
floor.
(6 in) to allow for caster removal.
2. Turn the key switch OFF and disconnect the bat-
7. Remove the caster brake wheels.
tery.
3. Lockout/Tagout truck as described in the Control of
Hazardous Energy section.

Fig. 4 (24055)
8. Remove the wire cover (2) from the caster wheel
assembly (6) and unplug both electric brake con-
nectors, PC643 and PC644. Refer to Figure 4.
9. Note the wire color and pin positions in connectors
JC643 and JC644 (1). Use extraction tool 062706
to remove the pins from the two connectors.
10. Use a hydraulic lift truck jack to support and lower
the caster and brake assembly during removal.
Remove the screw (7) holding the pin (8) in posi-
tion and then remove the caster and brake assem-
bly (9) from the truck. Retain the flatwashers (4)
and all other parts for reassembly.

M5.0-1457-008 Crown 2009 PF17433-8 Rev. 5/10

02 Rev. 5/10
566

11. Remove the retaining ring (1) from the axle. Refer
to Figure 5.
12. Remove the spacer (2) and the drum & bearing as-
sembly (3) from the axle.
13. Remove the three screws (4) that hold the disc
brake (5) to the axle. Remove the disc brake as
needed.
Fig. 5 (24056)
Caster Wheel and Brake Inspection
Refer to Figure 3.
• Measure the thickness (1) of the disc brake (10),
composed of the magnetic coil and friction plate.
Replace the disc brake (10) if the dimension (1) is
less than 28 mm (1.1 in). The magnetic coil and fric-
tion plate should always be replaced as a set.
• Inspect the surface of the brake coil. Replace the
disk brake if the electromagnetic coils are visible.
• Check to be sure the bearings in the brake drum
rotate freely. Refer to Bearing Installation in this
section for further information.
Crown 2009 PF17433-9 Rev. 5/10
BRAKE SYSTEM
Brake System
Drum and Bearing Assembly
Bearing Installation
Refer to Figure 6.
• Before installing the bearings (1), thoroughly clean
the brake drum bearing bores (2). Any burrs, dirt,
etc. must be removed before installing new bear-
ings.
• A press, vise or hammer and hardwood block that
fully covers the bearing can be used to install the
bearing. Whatever method is used, be sure the in-
stallation force is distributed equally over the entire
bearing surface to prevent the bearing from being
misaligned.
• When installed properly, the outboard bearing is re-
cessed in the hub. If you are using a press or vise
to install the bearing, a spacer that is slightly
smaller in diameter than the bearing is needed. If
using a hammer, recess the bearing with a brass
punch.
• After installing the bearings (1), check to be sure
that the bearings are fully seated and rotate freely.
Fig. 6 (21904)
M5.0-1457-009
02 Rev. 5/10
567
BRAKE SYSTEM
Brake System

Caster Wheel and Brake Installation
Refer to Figure 3.
Instructions are for one side at a time. Refer to Control
of Hazardous Energy for truck Lifting and Blocking pro-
cedures.
1. Feed the connector and wiring from the disc brake
coil through the axle weldment. Position the coil on
the axle weldment so that it is aligned with the
screw holes. Apply blue thread locking adhesive to
the three screws and attach the disc brake coil
from the axle side. Refer to figure 7.

Fig. 7 (24057)
2. Center the brake rotor on top of the coil. Center
four springs (1) on the tapped holes in the rotor.
Refer to Figure 8.

M5.0-1457-010 Crown 2009 PF17433-10 Rev. 5/10

02 Rev. 5/10
568

Fig. 8 (24058)
3. Place flatwashers (2) directly on top of the springs
as shown in Figure 8.
4. Install the drum & bearing assembly (1) onto the
axle making sure that the springs (2) are posi-
tioned below the counterbored holes and that the
slots (3) on the side of the brake drum are lined up
with the brake rotor tabs (4). It may be necessary
Fig. 9 (24059)
Crown 2009 PF17433-11 Rev. 5/10
BRAKE SYSTEM
Brake System
to rotate the drum to obtain the proper orientation.
Refer to Figure 9.
5. After the brake drum is in place, check all four
springs and flatwashers to make sure they are
properly positioned in the counterbored holes (5).
If any of them are cocked, use a screwdriver to
seat them in the counterbored holes (6).
M5.0-1457-011
02 Rev. 5/10
569
BRAKE SYSTEM
Brake System

6. Place the axle spacer (1) onto the axle. Refer to
Figure 10.
7. Install the retaining ring (2) to secure the assembly
in position.
8. Place the spacers with C-bore (3) in the brake
counterbored holes with the counterbored side of
the spacers facing up.

Fig. 10 (24060)

M5.0-1457-011 Crown 2009 PF17433-12 Rev. 5/10

02 Rev. 5/10
570

9. Start a grooveless retaining ring (2) on a spacer
(3). Put the retaining ring and spacer into the as-
sembly tool (1), Crown part number 132417, mak-
ing sure the lip (4) of the retaining ring is facing the
tool. Put the parts into a vice as shown in
Fig. 11 (24061)
10. Put a spacer and retaining ring assembly (1) into
each of the four holes in the brake assembly as
shown in Figure 12 with the lip of the retaining ring
facing down.
Fig. 12 (24062)
13. Turn the caster brake and axle assembly over and
assemble the second side in the same manner.
Crown 2009 PF17433-13 Rev. 5/10
BRAKE SYSTEM
Brake System
Figure 11. Slowly close the vise until the retaining
ring and spacer bottom out in the assembly tool.
Do not try to close the vise any further, to prevent
damage to the spacer or assembly tool.
11. Place flatwashers over the spacers.
12. Install the springs and screws into the spacers.
Finger tighten the screws, then torque them to 6.5
- 7.0 Nm (4.8-5.2 ft lb).
M5.0-1457-012
02 Rev. 5/10
571
BRAKE SYSTEM
Brake System

14. Push down on the top brake assembly to partially assembly to seat the bottom assembly. Turn the
seat the bottom assembly. Rotate the entire brake entire brake assembly over and repeat the process
assembly 180° and push down again on the top to seat the second brake assembly.

Fig. 13 (24063)
Note: Never set or drop the brake drum rotor assembly change the brake air gap and cause the brake or as-
when it is not in position on the axle. Doing so can sembly issues.

Fig. 14 (24064)
)

1 Bolt Head
2 Brake Drum Rotor Assembly
3 Brake Drum Rotor Assembly after being dropped on bold
heads

M5.0-1457-013 Crown 2009 PF17433-14 Rev. 5/10

02 Rev. 5/10
572
 BRAKE SYSTEM
Brake System

15. Use a hydraulic lift truck jack to raise the caster and 17. Install wires and pins into the connector bodies of
brake assembly (7) enough to feed the wires from JC643 and JC644 as previously removed.
JC643 and JC644 (1) through the hole in the axle.
18. Put the wire cover (2) on the assembly and secure
Raise the caster and brake assembly into position
it using one screw (3).
and mount it to the truck with the pin (9), making
sure the two flatwashers (4) are in position before 19. Install the caster wheels (6). Finger tighten all lug
totally inserting the pin. Refer to Figure 15. bolts (5), then torque them 60 to 75 Nm (45 to
55 ft lb).
16. Use the screw (8) to secure the pin (9) and assem-
bly (7) in position.

Fig. 15 (24065)
20. Remove the jack stands or other blocking material.
21. Remove the wheel chocks.
22. Connect the battery and check truck operation, es-
pecially caster brake operation, referring to Stop-
ping Distance in this section.

Crown 2009 PF17433-15 Rev. 5/10 M5.0-1457-014

02 Rev. 5/10
573