Crown Forklift WAVE 50 SERIES MAINTENANCE MANUAL

Description

Crown Forklift WAVE 50 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift WAVE 50 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

Language : English
Pages :268
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift WAVE 50 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

WAV50 1
Safety instructions 9
General maintenance 11
Equipment Cleaning 13
WAVE® Vehicle Procedures 13
Control of Hazardous Energy 14
Lockout/Tagout 14
WAVE® Work Assist Vehicle 14
Battery 14
Safety rules 14
Charging 15
Battery removal 16
Battery installation 16
Battery Lockout/Tagout 17
Hydraulic 18
Lifting and blocking 19
Mast 20
Capacitance 22
Introduction 23
Operator instructions 25
Service training 25
Publications 25
Data plate 26
Model number example 26
Vehicle data number example 27
LUBRICATION & adjustment 29
Maintenance program 31
Lubricants and maintenance products 32
Component Accessibility 33
Chassis 34
Load Deck (1) 34
Contactor Panel (2) 34
Rear Chassis Cover (3) 34
Service Panel (5) 35
MRC Controller 35
Battery Charger 35
Platform/Mast third Stage 36
Steering Control Pod (2) 37
Traction Control Pod (9) 37
Mast Cap (10) 37
Floorboard 37
Gates 37
Lubrication 38
Torque Values 48
Standard Screws/Bolts 48
Grade 48
Torque Chart – Standard Screws/Bolts 48
Self Locking Screw/Nuts 49
Grade 49
Torque Chart – Self Locking Screws/Nuts 49
HYDRAULIC SYStem 51
Hydraulic schematic symbols 53
Functional Description 54
Reservoir 54
Hydraulic Oils 54
Manual Lowering 55
Accumulator Operation 55
Hydraulic Lines and Fittings 56
Lift Relief Valve Setting 57
Accumulator 58
Precharging 59
Hydraulic Troubleshooting 60
Drive unit 63
Drive Unit Gearbox Lubrication 65
Gearbox Replacement 68
Wheels 69
Drive Wheel Replacement 70
Caster Wheel Replacement 71
Electrical maintenance 73
Component Accessability 76
Chassis (under load deck) 76
Chassis (under platform) 78
Steering Control Pod 79
Traction Control Pod 79
Platform Floor Components 80
Switches 81
Potentiometers 87
POT1 Steering Potentiometer 87
POT1 Steering Potentiometer Linkage Adjustment 87
POT2 Traction Potentiometer 89
Fuses 90
Control Cables 92
2135 mm (84 in) Lift Height 92
Control Cable Re-tension 93
Cable Replacement 94
2995 mm (118 in) Lift Height 96
Control Cable Re-tension 97
Cable Replacement 98
Keypad101
Keypad Programming Features102
Keypad Specifications103
Keypad Block Diagram103
Keypad Replacing Key Switch103
Part of Platform Wiring Diagram103
Wiring Color Codes104
Color104
Number104
System controller, CURTIS 1703107
Maintenance107
Safety107
Cleaning107
Special Tools108
Mini Fit Connector108
Curtis Handset108
Handset Operation109
Handset Menus111
Program Menu111
Faults Menu115
Functions Menu116
Information Menu116
Programmer Setup Menu116
Controller Settings117
Features and Calibration118
Handheld Programmer118
Cloning Controllers118
Feature Description119
Controller Troubleshooting127
Display Troubleshooting Indicators127
Handset Troubleshooting Aids128
Service Codes129
Hydraulic Interaction150
Static Condition150
Platform Raise152
Platform Lower154
Tilt Sensor156
Contactor157
Contactor ED (Emergency Disconnect) 24 V157
Inspection157
Contacts157
Coil157
Component Replacement158
Contact Replacement158
Coil Replacement159
Battery160
Battery Discharge Indicator, Lift Interrupt160
Battery161
Safety Rules162
Inspection162
Cleaning162
Maintenance Free Batteries162
Charger163
Charging Requirements163
Charging164
Abnormal Charge Sequence165
Battery Testing165
Troubleshooting166
Motors167
Inspection167
Traction Motor167
Removal167
Brush and Spring Removal167
Lift Pump Motor168
Removal168
Brush and Spring Removal168
Current Readings168
Service Panel169
Brake Maintenance173
Brake System175
Regenerative Braking175
Parking brake175
Parking Brake Wear176
MAST Maintenance177
2135 mm (84 in) Lift Height178
Torque Requirements179
Mast Disassembly179
Mast Maintenance180
Mast Assembly180
Mast Reshimming184
Top Shims and Guides184
Bottom Shims and Guides187
2995 mm (118 in) Lift Height188
Torque Requirements189
Mast Disassembly189
Mast Maintenance191
Mast Assembly191
Mast Reshimming196
Top Shims and Guides196
Bottom Shims and Guides199
Lift Chain200
Inspection200
Wear200
Rust and Corrosion201
Cracked Plates201
Tight Joints202
Protruding or Turned Pins202
Chain Side Wear202
Unequal Chain Tension202
Non Alignment of Lift Components202
Lift Chain Lubrication203
Lift Chain Replacement203
Lift Chain Removal203
Secondary Chain Replacement206
Leaf Chain Disconnect208
Cylinder Maintenance209
General211
Cylinder Removal212
Disassembly214
Hydraulic Seals215
Hydraulic Seal Installation215
Installation Tool216
Installation Procedure216
Cylinder Replacement218
Velocity Fuse Replacement221
Cylinder Bleeding222
Cylinder Summary222
Platform maintenance223
Load Tray225
Operation225
Load Tray Disassembly227
Load Tray Assembly227
Glossary229
Audible Indicators232
Battery232
Connections233
Contactors/Relays236
Diode Blocks237
Fuses237
Lights238
Miscellaneous239
Solenoid Valves242
Suppressor Blocks242
Switches243
System/Modules249
Electrical Diagrams251
Diagrams (2135 mm, 84 in)253
Block Diagram254
Schematic255
Platform256
Chassis257
Contactor Panel258
Power Cables259
Wire Harnesses260
Diagrams (2995 mm, 118 in)261
Block Diagram262
Schematic263
Platform264
Chassis265
Contactor Panel266
Power Cables267
Wire Harnesses268

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