service repair manual

1. WAV 50 Series
Order Number: 812718-006
Printed in Germany ● Revision Level A
Parts Manual

2. 1
Printed in Germany
TABLE OF CONTENT

3. 3
M1.0-0000-0003
3
MP-WAV 50 05/05 • Printed in Germany
TABLE OF CONTENT
MP-IDX-2350
Table of Content
ITD – INTRODUCTION PAGE SERIAL NR. CUT REV.
General ................................................................................. 7
SECTION 1 – COVERS PAGE SERIAL NR. CUT REV.
Chassis Front ........................................................................ 12, 14
Chassis Rear ........................................................................ 16
Axle ....................................................................................... 18
SECTION 2 – HYDRAULIC PART PAGE SERIAL NR. CUT REV.
Hydraulic Unit ....................................................................... 22
SECTION 3 – DRIVE UNIT PAGE SERIAL NR. CUT REV.
Drive Wheel........................................................................... 26
SECTION 4 – ELECTRICAL PAGE SERIAL NR. CUT REV.
Electrical Parts ..................................................................... 30, 32, 34
Contactor .............................................................................. 36
Traction Handle ..................................................................... 38
Steering Handle..................................................................... 40, 42
Service Panel ........................................................................ 44
Mast Wiring ........................................................................... 46, 48
Gate Switch........................................................................... 50
Height Switch ........................................................................ 52
Motor Cover Switch .............................................................. 54
SECTION 7 – MAST-/LIFT STRUCTURE PAGE SERIAL NR. CUT REV.
Mast ...................................................................................... 58, 60, 62
Mast Chain ............................................................................ 64, 66
Yoke ...................................................................................... 68
SECTION 8 – CYLINDER PAGE SERIAL NR. CUT REV.
Lift Cylinder ........................................................................... 72
SECTION9 – CABIN/PLATFORM PAGE SERIAL NR. CUT REV.
Platform ................................................................................. 76, 78, 80
SECTION10 – MISCELLANEOUS SERVICE INF. PAGE SERIAL NR. CUT REV.
Rail Guide ............................................................................. 84
Load Tray ............................................................................... 86
Labels and Decals................................................................. 88, 90

4. 5
Printed in Germany
INTRODUCTION

5. 7
M1.0-0000-0007
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MP-WAV 50 05/05 • Printed in Germany
INTRODUCTION
MP-WAV 50 05/05 • Printed in Germany M/P-ITD-2350
Important customer information
To ensure the safety of the truck, you, the customer,
must only carry out maintenance and repairs as
stipulated in the operator manual.
Any additional work must be performed by Crown
authorised service technicians. Authorised service
technicians have the required expertise and up-to-date
service information.
If you wish to have your own technicians trained, please
contact Crown for relevant training courses.
Subsequent Attachments and Modifications
made to the Truck
DANGER!
Any proposed modification which would
alter the original condition of the truck
when delivered, must first be assessed and
approved in writing by Crown Gabelstapler
GmbH.
● The net weight and position of
attachments may considerably affect the
capacity and other truck characteristics.
● Changing the electrical system or adding
electrically operated components may
result in operating faults.
Modifications which have not been assessed may
result in fatal accidents!
Ordering Spare Parts
Spare parts can be ordered by quoting:
● The truck specification number
● The truck model number
● The truck serial number
This information can be found on the truck's data plate.
Only if this information is provided can the order be
processed quickly, correctly and reliably.
Please refer to the Technical Specifications Sheet for the
utilisable loads, technical data and dimensions for this
series. Brochures can be obtained from your CROWN
dealer or from the following address:
CROWN Gabelstapler GmbH & CoKG
Moosacher Str. 52
80809 Munich
GERMANY
Tel.: +49 (0)89 / 93 002 -0
Fax: +49 (0)89 / 93 002 -175 oder 133

6. Printed in Germany
9
PARTS

7. Printed in Germany
11
SECTION 1

8. M1.0-0000-00012
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MP-WAV 50 05/05 • Printed in Germany
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Positive
Terminal
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Negative
Terminal
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14
FU3
FU
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10
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D
D
MP-1.0-2350
MP-2350-001
CHASSIS FRONT
Part 1-3
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Cover Screw
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9. 13
MP-WAV 50 05/05 • Printed in Germany
INDEX PART NUMBER PART NAME NUMBER REQUIRED
Always Specify Model & Serial Number
To select part number, refer to truck data number.
See Section ITD
MP-1.0-2350
CHASSIS FRONT
1..................... 128748 ..................................... Cover ...................................................................................................... 1
120390 ..................................... Panel ....................................................................................................... 1
130788 ..................................... Front Bracket .......................................................................................... 2
130789 ..................................... Rear Bracket........................................................................................... 2
061094-002 .............................. Screw...................................................................................................... 8
120533 ..................................... Plug ......................................................................................................... 4
2..................... 125323 ..................................... Battery .................................................................................................... 4
060005-008 .............................. Washer ................................................................................................... 8
060030-017 .............................. Washer ................................................................................................... 8
3..................... 125784 ..................................... Bracket ................................................................................................... 2
060024-002 .............................. Nut .......................................................................................................... 2
060030-017 .............................. Washer ................................................................................................... 2
4..................... 120383 ..................................... Rod ......................................................................................................... 2
060000-045 .............................. Roll Pin ................................................................................................... 2
120382 ..................................... Rod Assembly ........................................................................................ 2
5..................... 120241 ..................................... Battery Tray ............................................................................................. 2
6..................... 120251 ..................................... Side Bumper ........................................................................................... 2
060080-007 .............................. Nut .......................................................................................................... 6
060030-098 .............................. Washer ................................................................................................... 6
7..................... 078723-005 .............................. Connector Gray ...................................................................................... 2
078724-005 .............................. Contacts ................................................................................................. 2
060012-078 .............................. Screw...................................................................................................... 2
8..................... 120573 ..................................... Handle .................................................................................................... 1
060012-078 .............................. Screw...................................................................................................... 2
9..................... 060016-096 .............................. Screw...................................................................................................... 2
060030-017 .............................. Washer ................................................................................................... 2
10.................... 120391 ..................................... Front Bumper .......................................................................................... 1
060017-104 .............................. Screw...................................................................................................... 4
11.................... 120357-001 .............................. Side Cover LH ........................................................................................ 1
120357-002 .............................. Side Cover RH........................................................................................ 1
12....................................................................... Service Panel (see Section 4.8).............................................................. 1
120604 ..................................... Spring ..................................................................................................... 1
103418-035 .............................. Spacer .................................................................................................... 2
060030-197 .............................. Washer ................................................................................................... 2
060017-103 .............................. Screw...................................................................................................... 2
13.................... 120202-003 .............................. Battery Charger (220V, 25 A EEC) ......................................................... 1
120202-004 .............................. Battery Charger (240V, 25 A AUS) ......................................................... 1
127039-003 .............................. Circuit Breaker (7 A) ............................................................................... 1
127038-001 .............................. Fuse ........................................................................................................ 1
127037 ..................................... Fuse Holder ............................................................................................ 1
060016-095 .............................. Screw...................................................................................................... 4
795730 ..................................... AC Power Cord (UK) .............................................................................. 1
795731 ..................................... AC Power Cord (EEC) ............................................................................ 1
14....................................................................... Hydraulic Unit (see Section 2.0) ............................................................. 1
120314 ..................................... Vibration Mount ....................................................................................... 3
060080-006 .............................. Nut .......................................................................................................... 3
15....................................................................... Contactor Panel (see Section 4.1) .......................................................... 1
060080-008 .............................. Nut .......................................................................................................... 2
16.................... 133085 ..................................... Controller ................................................................................................ 1
133085-00R-0S ........................ Remanufactured MRC Controller ............................................................ 1
060015-003 .............................. Screw...................................................................................................... 6
060005-007 .............................. Washer ................................................................................................... 6
060021-006 .............................. Nut .......................................................................................................... 6
120433 ..................................... Controller Mounting Plate ........................................................................ 1
060014-080 .............................. Screw...................................................................................................... 6

10. M1.0-0000-00014
M1.0-0000-00014
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MP-WAV 50 05/05 • Printed in Germany
1
2 3
4
5
16
16
7
8
17
12
12
13
14
15
6
11
18
12
19
20
21
1
1
+
Positive
Terminal
–
Negative
Terminal
B
a
tte
ry
#
1
B
a
tte
ry
#
3
14
FU3
FU
2
B
a
tt
e
ry
C
h
a
rg
e
r
Ma
de
in
U.S
.A.
Inp
ut
Vo
ltag
e:
12
0V
.
AC
Ou
tpu
t
Vo
ltag
e:
24
V.
DC
12
0V
A
C
IN
24
V
D
C
O
U
T
R
E
S
E
T
S
E
A
L
E
D
W
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T
B
10
B
9
10
6
A
A
C
C
D
D
MP-1.0-2350
MP-2350-001
CHASSIS FRONT
Part 2-3
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Cover Screw
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11. 15
MP-WAV 50 05/05 • Printed in Germany
INDEX PART NUMBER PART NAME NUMBER REQUIRED
Always Specify Model & Serial Number
To select part number, refer to truck data number.
See Section ITD
MP-1.0-2350
CHASSIS FRONT
17....................................................................... Front Axle (see Section 1.5).................................................................... 1
18.................... 120320-002 .............................. Chassis 2135 mm (84 in.) (see Section 7.2) ........................................... 1
120320-003 .............................. Chassis 2995 mm (118 in.) (see Section 7.2) ......................................... 1
19.................... 125684 ..................................... Cap ......................................................................................................... 2
125685 ..................................... Tube ........................................................................................................ 1
125691 ..................................... Strap Velcro............................................................................................. 2
20.................... 065004-013 .............................. Grommet ................................................................................................. 2
21.................... 065004-014 .............................. Grommet ................................................................................................. 2

12. M1.0-0000-00016
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2
1
TB201
TB202
1
2
3
4
5
6
7
8
9
1
0
1
1
1
3
1
2
1
4
0
61 Nm
(45 ft. lbs.)
MP-1.0-2350
MP-2350-002
CHASSIS REAR
Part 3-3 O
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MP-WAV 50 05/05 • Printed in Germany
INDEX PART NUMBER PART NAME NUMBER REQUIRED
Always Specify Model & Serial Number
To select part number, refer to truck data number.
See Section ITD
MP-1.0-2350
CHASSIS REAR
1..................... 065004-013 .............................. Grommet ................................................................................................. 1
2..................... 075256 ..................................... Diode....................................................................................................... 1
060012-079 .............................. Screw...................................................................................................... 2
3..................... 102126-003 .............................. Static Ground Strap ................................................................................ 1
060017-105 .............................. Screw...................................................................................................... 1
4..................... 120394 ..................................... Rear Bumper........................................................................................... 1
060080-007 .............................. Nut .......................................................................................................... 4
5..................... 120310 ..................................... Shim Pad................................................................................................. 2
060015-023 .............................. Screw...................................................................................................... 4
6..................... 120553 ..................................... Drive Motor & Brake Assembly............................................................... 2
060015-064 .............................. Screw...................................................................................................... 8
120581 ..................................... Brush & Cap Kit ...................................................................................... 2
060005-007 .............................. Washer ................................................................................................... 8
120421 ..................................... Drive Unit Assembly (included 5, 6, 7, 9, 10, & 11)................................. 2
126012 ..................................... Brake Assembly ..................................................................................... 2
7..................... 120570 ..................................... Drive Unit ................................................................................................ 2
125764 ..................................... Input Oil Seal .......................................................................................... 1
125765 ..................................... Output Oil Seal ....................................................................................... 1
132246 ..................................... Baffle Vent ............................................................................................... 2
060017-071 .............................. Screw...................................................................................................... 6
060030-197 .............................. Washer ................................................................................................... 6
060021-011 .............................. Nut .......................................................................................................... 6
061004-026 .............................. Adhesive ................................................................................................. AR
8..................... 079564-013 .............................. Terminal Board ........................................................................................ 2
079565-013 .............................. Label ....................................................................................................... 2
060012-077 .............................. Screw...................................................................................................... 4
9..................... 120534 ..................................... Coupler ................................................................................................... 4
125999 ..................................... Drive Motor Coupling Kit (included 9, 10 & 11) ....................................... 2
10.................... 120535 ..................................... Insert Coupler ......................................................................................... 2
11.................... 103418-038 .............................. Spacer .................................................................................................... 2

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15. M1.0-0000-00018
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MP-WAV 50 05/05 • Printed in Germany
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2
3
3
3
4
5
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3
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14
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8
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15
A
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MP-1.5-2350
MP-2350-003
AXLE
Chassis
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16. 19
MP-WAV 50 05/05 • Printed in Germany
INDEX PART NUMBER PART NAME NUMBER REQUIRED
Always Specify Model & Serial Number
To select part number, refer to truck data number.
See Section ITD
MP-1.5-2350
AXLE
0..................... 120362 ..................................... Axel (included 2, 3, 5, 6, 7 & 14) ............................................................. 1
1..................... 120580 ..................................... Cap ......................................................................................................... 2
2........................... 060009-086 .............................. Retaining Ring ................................................................................... 2
3........................... 125710 ..................................... Caster Wheel Assembly .................................................................... 2
120578-001 ............................... Caster Wheel ............................................................................... 2
065081-023 ............................... Bearing Ball ................................................................................. 8
4..................... 100779 ..................................... Grease Nipple ......................................................................................... 1
5........................... 120373-002 .............................. Caster Mount RH .............................................................................. 1
6........................... 065117-003 .............................. Bushing ............................................................................................. 2
7........................... 120363 ..................................... Axle ................................................................................................... 1
8..................... 120398 ..................................... Shaft........................................................................................................ 1
9..................... 060017-104 .............................. Screw...................................................................................................... 1
10.................... 064091-009 .............................. Hex Plug ................................................................................................. 2
11.................... 102414 ..................................... Spring ..................................................................................................... 2
12.................... 120370 ..................................... Friction Bar .............................................................................................. 2
13.................... 060009-086 .............................. Retaining Ring ........................................................................................ 2
14.......................... 120373-001 .............................. Caster Mount LH ............................................................................... 1
15.................... 060030-148 .............................. Washer ................................................................................................... AR
16.................... 133849 ..................................... Screw...................................................................................................... 2
17.................... 060080-008 .............................. Nut .......................................................................................................... 2
18.................... 060000-065 .............................. Roll Pin ................................................................................................... 2