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Crown SP3500:
Wire Guidance Coil Saturated & will not calibrate

I have a SP3500 that will not calibrate with forks leading. When calibrating the coil there is message that coil is saturated; but I have verified height and replaced both sensor bars. The manual states a saturated coil should not prevent calibration. I have also verified field strength and receive same message over multiple wires in the warehouse.
After calibrating the coil/sensor bars (running over wire 2+ times at 5 degrees) I attempt to calibrate on the wire and forks trailing it gets to 100% no problem; but as soon as I change direction to forks leading, the SP will start to veer right until it falls off wire.
ECR2 is calibrated at index, no issue.
New drive tire and there does not seem to be excessive movement in the drive assembly
All 4 load wheels are relatively new and free turning.
  • Posted 27 Dec 2017 23:54
  • Discussion started by margaret_w
  • Arizona, United States
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Showing items 1 - 10 of 10 results.
Finally figured this one out. Brake Coil was bad.
  • Posted 3 May 2018 19:26
  • Reply by margaret_w
  • Arizona, United States
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Also check for "stray" frequency! I just had one that exhibited the same symptoms. Turns out the coils were being saturated by frequency emitted from the drive motor. It would never acquire the wire and the drive unit would hunt back and forth while trying to align. Unfortunately, the drive motor had to be replaced.
  • Posted 3 Feb 2018 13:18
  • Reply by Tech541
  • Ohio, United States
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Thanks Popeye & PESLLC, I will check these things. It is an older SP, so I was wondering about stray voltage.
  • Posted 3 Jan 2018 15:20
  • Reply by margaret_w
  • Arizona, United States
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Have you tried to raise the sensor to see of the scales change. This may help determine if the issue is even sensor related. I have also had a goofy truck that no matter what we did the sensor read saturated. I ended up making an extension to the bracket to raise it about.5" above the max. It has been running fine for over a year now.
  • Posted 3 Jan 2018 07:41
  • Reply by PESLLC
  • fl
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Check for voltage to frame before and after engaging traction you might find a bad drive motor or Access #3 putting voltage to frame and the sensors are picking it up. Might be brake coil also, but I have not seen that since old SP days.
  • Posted 31 Dec 2017 00:48
  • Reply by popeye
  • Ohio, United States
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Thanks Popeye, that was a good idea. Interesting, when off the wire, I am getting 00,00,01,00 on both GS1 & GS2; however, as soon as I engage the traction (move traction handle either PUF or FF) both sensors go to something near 80,99,99,80 (in other words-saturated).
So tonight I am going to try Ifixit's idea and try swapping out modules 5 & 6 to see if either changes behavior, as well as look for loose or frayed wire that may be causing the input voltage.

If anyone has ideas on where to look for voltage appearing to be sensor pickup when off wire, tips are appreciated.
  • Posted 29 Dec 2017 16:02
  • Reply by margaret_w
  • Arizona, United States
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On the sensor bar between the load wheels is it the correct one for your floor power. Crown has both low and high gain depending on power from wire in floor. You can eyeball truck centered up on the wire then go in through the display and look at GS1 and GS2 inputs to see what the sensors are seeing. You will see 4 sets of 2 digit numbers. 2 middle sets are the ones on each side of wire and other 2 are the outside sensors.
  • Posted 29 Dec 2017 08:22
  • Reply by popeye
  • Ohio, United States
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On the bright side, you have a lot of donor trucks to swap parts with to see if the problem stays or moves to the other truck
  • Posted 28 Dec 2017 23:05
  • Reply by Ifixit
  • Pennsylvania, United States
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Thanks Ifixit, I have checked for all the usual mechanical reasons; but the source seems to be the "saturated coil" message. The SP thinks it is "on the wire" even when it is not. We have 50 SP in the same area and this is the only one exhibiting this issue; so I doubt it is the transmitter (floor wire). I have changed out both sensor bars and am not receiving any fault/event codes associated with WGU except the 636.
  • Posted 28 Dec 2017 22:24
  • Reply by margaret_w
  • Arizona, United States
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I'm taking a guess, here. Have you checked the steer bearing? Sits above the drive unit. I've seen them start to go bad and physically steer the truck off line.
  • Posted 28 Dec 2017 17:46
  • Reply by Ifixit
  • Pennsylvania, United States
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"This seems like a broken wire in the loom that you move, or a wire loose on one of the pins."
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