PDF Service Manual Crown Forklift Wav 50 - 2 MB
Get the technical information you need to service the Crown Wav 50 Work Assist Vehicle.
This comprehensive service manual contains detailed troubleshooting guides, repair procedures, and system schematics.
It is designed for trained technicians to perform maintenance and repairs accurately and efficiently.
Keep your Crown Wav 50 operating safely and reduce downtime with this official manual.
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--- Page 1 ---
Crown Manual of Responsibility
For The User
C
2000 PF11782-1 Rev. 3/01
®
--- Page 3 ---
INTRODUCTION
The vehicle data number provides you and your dealer with a wealth of information to ensure the selection of proper parts
for your vehicle. You may simply provide this number to your dealer, or use the following breakdown if selecting your own
part numbers or service information from this manual.
VEHICLE DATA NUMBER EXAMPLE
Alarms
A = Forward K = Lift Lower
B = Reverse L = Forward
C = Lift Reverse Lift
D = Lower M = Forward
E = Forward Reverse Lower
Reverse N = Reverse Lift
Color F = Forward Lift Lower
1 = Maui Yellow H = Forward O = Forward Lift
2 = Seafoam Green Lower Lower
3 = Alpine White I = Reverse Lift P = Forward
J = Reverse Lower Reverse Lift, Lower
Battery Charger Q = None
1 = 15 Amp.
2 = 25 Amp. Meter
KE = No Hour Meter
Lift Height
HM = Hour Meter
70 = 1780mm (70 in.)
84 = 2135mm (84 in.) Storage
– = No Storage
1 = One Pocket
–841221AHM12351 2 = Two Pockets
Vehicle System Controller
– = Standard – = No Handset
C = Custom 1 = Handset
S = Special
Batteries
1 = Wet 160 Amp. Aisle Guide
2 = Wet 205 Amp. -- = No Guidance
3 = Maintenance Free 195 Amp. 35 = Actual Width
Wheel Color
1 = Yellow
2 = Black Strobe
– = No Strobe
1 = Strobe
6202-02
The example of the vehicle data number shown above is a standard vehicle with a 2135 mm (84 in.) lift height, 160 Amp.
wet cell batteries, with a 25 Amp. battery charger, vehicle color of Seafoam Green, yellow wheels, with a forward travel
alarm, equipped with; an hour meter, strobe light, one (1) storage pocket, aisle guidance and system controller with a
handset.
ITD–2350–006
®
Crown 2000 PF11778-3 Rev. 3/01 01 REV. 3/01
--- Page 4 ---
CONTROL OF HAZARDOUS ENERGY
Hydraulic
When maintenance is to be performed on the hydraulic
system, make sure the hydraulic system is not under pres-
sure:
AVOID HIGH PRESSURE FLUIDS—Escaping
fluid under pressure can penetrate the skin caus-
1. Move vehicle to a secure non-traffic maintenance area
ing serious injury. Relieve pressure before dis-
with a level floor.
connecting hydraulic lines. Tighten all connec-
tions before applying pressure. Keep hands and
2. No load on load tray or load deck.
body away from pin holes which eject fluids under
high pressure. Use a piece of cardboard or paper
3. Completely lower load engaging means or, if required
to search for leaks. Do not use your hand.
for maintenance, block vehicle at appropriate height
as described in Lifting and Blocking of this section.
Any fluid injected into the skin under high pres-
sure should be considered as a serious medical
4. Actuate the hydraulic switch to remove any hydraulic
emergency despite an initial normal appearance
pressure that may be present.
of the skin. There is a delayed onset of pain, and
serious tissue damage may occur. Medical atten-
5. Lockout or tagout vehicle as described in Lockout -
tion should be sought immediately by a specialist
Tagout in this section.
who has had experience with this type of injury.
No Load
On Tray
Platform
Completely Lowered
Figure 17607
MA–2350–102
®
Crown 2004 PF13894-3 Rev. 10/09 01 Rev. 10/09
--- Page 5 ---
LUBRICATION & ADJUSTMENT
I-6
I-1
I-7
I-8 I-11 I-13
I-1
I-1
I-7
I-9
I-1 R
N
IN nt
rese
From
Bat
G
Kee
p
tery
Fire
FU
A
esP
y
Gas
Awa
2
W ee
Exp
losiv
Flam 14
FU3
And
G p
Fire
IN nt
Kee
tery
N rese
Bat
R From
A
esP
y
Gas
Awa
W ee
losiv
Flam
Exp
And
RE
SE
T
I-11
SE
AL
ED
Ba
Ch W
ET
Input
Outpu artte
gery
Volta
t
Volta ge:
r
ge: 120V
24V. .
AC
Made
DC
in
U.S.A
.
24V
DC
OU
T
120
V
AC
IN
I-3
I-14
I-2 I-10
I-1
I-12
I-4
I-3
I-1
I-5 I-15
I-3
NOTE: Platform Shown Partially Elevated and Service
Panel Open For Illustration Purposes.
6151-01
ILLUSTRATION 4
INSPECTION AND ADJUSTMENT CHART 1-4
CHASSIS FRONT
90 da. 180 da. 270 da. 360 da.
INDEX COMPONENT 150 hr. 300 hr. 450 hr. 600 hr.
I-1 Electrical i.e.: Connectors, Cables and Wiring Check
I-2 Front Axle and Casters Check
I-3 Wheels, Front & Rear Check
I-4 Service Panel Check
I-5 Front Strobe Light (Optional) Check
I-6 Load Deck Check
I-7 Batteries i.e.; For Leakage, Cracks & Corrosion Check
I-8 Battery Connector Check
I-9 Contactor Panel Check
I-10 Hydraulic Assembly i.e.; Pump, Motor (M3) Check
I-11 Hydraulic Accumulator, and Reservoir Filler Cap Check
I-12 Battery Charger Check
I-13 Dynamic Cable Tension Area Check
I-14 Chassis Side Covers Check
I-15 MRC Controller Check
Refer to appropriate section of service manual for additional information concerning inspection and/or adjustment.
Note: Hours are based on traction hours which is accessible by using Curtis handset.
M1.0–2350–013
®
Crown 1997 PF11193-4 Rev. 3/01 04 REV. 3/01
--- Page 6 ---
HYDRAULIC TROUBLESHOOTING
Symptom Probable Cause Remedy
No cushion during raise or lower Accumulator malfunction Charge accumulator properly. Refer
to section M2.6.
Will not lift capacity load Relief valve not adjusted properly Adjust relief valve.
Mast binding Inspect mast for damage,
misalignment, etc.
Hydraulic component(s) malfunction Refer to hydraulic system M2.0.
Platform drifts down Debris in solenoid valve Cycle through lift/lower to free
possible debris.
Lift cylinder packings leaking Refer to cylinder information section
M2.6.
Accumulator loses charge Accumulator valve leaking, cracked, Repair. Refer to accumulator
deformed, etc. maintenance section M2.6.
Abnormal hydraulic oil usage External leak Check plumbing, cylinder, other
hydraulic components.
Lift pump & motor overheating * Exceeding capacity load Check load weight.
Worn or damaged pump & motor Inspect pump & motor. Repair or
replace.
Fluid level low Inspect fluid level. Fill system to
proper level. Refer to section M2.0.
Failure of platform to raise and Lift chains not adjusted properly Adjust chains.
lower smoothly
Mast and/or platform binding Inspect mast & platform for damage,
wear, etc.
Hydraulic component malfunction Inspect pump, motor, valve, cylinder,
etc. for damage, leaks, wear, etc.
Accumulator malfunction Refer to section M2.6.
Air trapped in cylinder Bleed.
* Be sure the vehicle has been performing its normal duty cycle at this time.
M2.9–2350–002
®
Crown 1997 PF11204-2 Rev. 3/01 02 REV. 3/01
--- Page 7 ---
ELECTRICAL MAINTENANCE
Component Accessability
Chassis (under load deck) Components
• Lift load deck from vehicle.
Load Deck
Emergency
Disconnect
Suppressor Contactor (ED)
(SB83)
Fuses
FU-2 & FU-3
Filter
Travel
Battery Block (SB81)
Alarm (ALM)
Disconnect
Batteries Horn (HN) &
A Ga
RsesPFro
Wsivme
e
plo
Ex d
Aw
Fla
ay
IN
N resm
G ep
t
enBa
Ke
tte