Wave 50 Series PDF

MAINTENANCE MANUAL
WAVE 50 SERIES
Order Number: 812562-006

Revision: A • Printed in Germany
This master maintenance manual is subject to continual updates.
It is meant exclusively for businesses authorized by CROWN.
It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG

– European Headquarter –
Moosacher Str. 52
80809 München
Germany
Phone +49 (0)89 93 00 2 – 0

Fax +49 (0)89 93 00 2 – 133
All rights reserved under international and Pan-American Copyright Agreement.

Copyright 2005
CROWN Equipment Corporation
TABLE OF CONTENTS
MA- SAFETY INSTRUCTIONS PAGE

General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
WAVE® Vehicle Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control of Hazardous Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Lockout/Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WAVE® Work Assist Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lifting and blocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 INTRODUCTION PAGE
Operator instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Model number example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Vehicle data number example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
M1- LUBRICATION & ADJUSTMENT PAGE

Maintenance program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lubricants and maintenance products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Component Accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Load Deck (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Contactor Panel (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rear Chassis Cover (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Service Panel (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MRC Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Platform/Mast third Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Steering Control Pod (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Traction Control Pod (9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mast Cap (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Floorboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Standard Screws/Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Torque Chart – Standard Screws/Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Self Locking Screw/Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Torque Chart – Self Locking Screws/Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
WAVE 50 10/2005 • Printed in Germany
I
M2- HYDRAULIC SYSTEM PAGE
Hydraulic schematic symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hydraulic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Manual Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Accumulator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hydraulic Lines and Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Lift Relief Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Precharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Hydraulic Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
M3- DRIVE UNIT PAGE

Drive Unit Gearbox Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Gearbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Drive Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Caster Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
M4- ELECTRICAL MAINTENANCE PAGE

Component Accessability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Chassis (under load deck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Chassis (under platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Steering Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Traction Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Platform Floor Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
POT1 Steering Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
POT1 Steering Potentiometer Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
POT2 Traction Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2135 mm (84 in) Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Control Cable Re-tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2995 mm (118 in) Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Control Cable Re-tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Keypad Programming Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Keypad Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Keypad Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Keypad Replacing Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Part of Platform Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Wiring Color Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
II
System controller, CURTIS 1703 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Mini Fit Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Curtis Handset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Handset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Handset Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Faults Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Functions Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Information Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Programmer Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Controller Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Features and Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Handheld Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Cloning Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Feature Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Controller Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Display Troubleshooting Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Handset Troubleshooting Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Hydraulic Interaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Static Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Platform Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Platform Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Contactor ED (Emergency Disconnect) 24 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Contact Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Coil Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Battery Discharge Indicator,
Lift Interrupt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Safety Rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Maintenance Free Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Charging Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Lift Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Current Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
III
Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
M5- BRAKE MAINTENANCE PAGE

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Regenerative Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Parking Brake Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
M7- MAST MAINTENANCE PAGE

2135 mm (84 in) Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Mast Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Mast Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Mast Reshimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Top Shims and Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Bottom Shims and Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2995 mm (118 in) Lift Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Mast Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Mast Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Mast Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Mast Reshimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Top Shims and Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Bottom Shims and Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Lift Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Rust and Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Cracked Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Tight Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Protruding or Turned Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Chain Side Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Lift Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Lift Chain Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Secondary Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Leaf Chain Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
M8- CYLINDER MAINTENANCE PAGE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Hydraulic Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Hydraulic Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Velocity Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Cylinder Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Cylinder Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
IV
M9- PLATFORM MAINTENANCE PAGE
Load Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Load Tray Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Load Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
M10-GLOSSARY PAGE
Audible Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Contactors/Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Diode Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Suppressor Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
System/Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
DIA- ELECTRICAL DIAGRAMS PAGE

Diagrams (2135 mm, 84 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Diagrams (2995 mm, 118 in) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Contactor Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
V
VI WAVE 50 10/2005 • Printed in Germany
SAFETY INSTRUCTIONS
Printed in Germany
1
SAFETY INSTRUCTIONS
Notice:
Printed in Germany
2
SAFETY INSTRUCTIONS
General maintenance
General maintenance – Use chocks or other positive positioning de-

vices.
– Block load engaging means, inter masts or
Warning! Risk of accident! chassis before working under them.
To prevent serious risk of injury – Operation to check performance of vehicle or
to yourself and others observe attachments shall be conducted in an author-
the following safety instruc- ized safe clearance area.
tions.
z Before starting to operate the vehicle:
These vehicles may become hazardous if adequate – Be in operating position.
maintenance is neglected. Therefore, adequate main-
tenance facilities, trained personnel and procedures – Place directional control in neutral.
should be provided. – Before operating the vehicle, check the func-
tions of lift systems, directional control, speed
Maintenance and inspection shall be performed in con- control, steering, warning devices and brakes.
formance with the following practices:
z A scheduled planned maintenance, lubrication and Warning! Fire hazard!

inspection system should be followed.
Fire or flame can cause severe
z Only qualified and authorized personnel shall be personal injury or property
permitted to maintain, repair, adjust and inspect damage.
vehicle. Do not use an open flame to
check level or for leakage of
z Before leaving the vehicle: electrolyte and fluids or oil.
Do not use open pans of fuel or
– Stop the vehicle. flammable cleaning fluids for
– Fully lower the platform. cleaning parts.
– Place directional controls in neutral. z Avoid fire hazards and have fire protection equip-
– Turn off power (Battery disconnect). ment present.
– Remove key. z Keep shop well ventilated, clean and dry.

– Block the wheels if vehicle is on an incline.
z Brakes, steering mechanisms, control mecha-
z Before working on the vehicle nisms, guards and safety devices shall be in-
spected regularly and maintained in a safe operat-
– Raise drive wheels free of floor or disconnect ing condition.
power sources.
WAVE 50 10/2005 • Printed in Germany MA-2450
02 Rev. 12/01
3
SAFETY INSTRUCTIONS
General maintenance
z Capacity, operation and maintenance instruction z Vehicles shall be kept in a clean condition to mini-
plates or decals shall be maintained in legible con- mize fire hazards and facilitate detection of loose
dition. or defective parts.
z All parts of lift mechanisms shall be inspected to z Modifications and additions which affect capacity
maintain them in safe operating condition. and safe vehicle operation shall not be performed
by the customer or user without manufacturers
z All hydraulic systems shall be regularly inspected prior written approval. Capacity, operation and
and maintained in conformance with good practice. maintenance plates or decals shall be changed ac-
Cylinders, valves and other similar parts shall be cordingly.
checked to assure that “drift” has not developed to
the extent that it would create a hazard. z Care shall be taken to assure that all replacement
parts are interchangeable with the original parts
z Batteries, motors, controllers, limit switches, pro- and of equal quality to that provided in the original
tective devices, electrical conductors and connec- equipment.
tions shall be maintained in conformance with
good practice. Special attention shall be paid to the z Be sure that any equipment added to the truck (ter-
condition of electrical insulation. minal, fan, clipboard, etc.) is positioned so that it
does not block your vision or interfere with safe and
efficient operation of the truck.
MA-2450 WAVE 50 10/2005 • Printed in Germany
02 Rev. 12/01
4
SAFETY INSTRUCTIONS
Equipment Cleaning
Equipment Cleaning Functional integrity of contaminated components may

be questionable. Nuisance fault logging, intermittent
operation or immediate failure could be the resultant of
power washing.
WAVE® Vehicle Procedures
Power washing will also remove and/or destroy lubri-
z Prefer dry pressured air for cleaning built up dirt cants in or on the surface of shafts, unsealed bearings,
and dust from electric material handling equip- hinges, exposed gears, bushings, chains, linkages,
ment. etc.
z For localized degreasing use of an appropriate sol- z These items must also be protected before clean-
vent such as "TOUGH ON GREASE" (Crown P/N ing or properly lubricated after cleaning.
063009-005) is recommended.
Consideration must also be given to metal surfaces.
If these methods are not effective and power washing The cleaning process can strip away paint and protec-
is the only alternative, extreme care must be exercised. tive coatings applied to components (i.e. hydraulic
lines, terminal strips, linkages) for freezer/corrosion en-
vironment.
Caution! Risk of damage!
Power washing or cleaning sol- z Paint and/or protective coating must be reapplied
vents can damage electrical to these areas to reduce the chance of oxidation
components including connec- and corrosion.
tors, terminal boards and wir-
ing. z Remove solvent residue and dry the component
Mineral and chemical residue thoroughly before installing removed components,
left on or in components (i.e. cir- lubricating or returning the equipment to service.
cuit boards, contactors, encod-
ers, switches, potentiometers,
etc.) after washing is a propo-
nent of oxidation and corrosion.
All electronic components in-
cluding motors must be pro-
tected or even removed to elim-
inate the risk of damage.
5
SAFETY INSTRUCTIONS
Control of Hazardous Energy
Control of Hazardous Energy z If electrolyte comes in contact with eyes, flush im-
mediately and thoroughly with clean water. Obtain
medical attention immediately.
Lockout/Tagout z Should electrolyte be spilled on skin, rinse
promptly with clean water and wash with soap.
WAVE® Work Assist Vehicle z A baking soda solution (one pound to one gallon of
water) will neutralize acid spilled on clothing, floor
In the interest of safety and to ensure compliance with or any other surface. Apply solution until bubbling
the OSHA Regulations, (Standards - 29 CFR), The stops and rinse with clean water.
control of hazardous energy (lockout/tagout) -
1910.147, Crown has developed guidelines for proper z Keep vent plugs firmly in place at all times except
energy control when performing service and mainte- when adding water or taking hydrometer readings.
nance on the WAVE.
z Review the appropriate sections in this service Danger! Risk of explosion!

manual for additional procedures to be followed,
before performing any service or maintenance on Gas formed during charging is
the WAVE. highly explosive and can cause
serious personal injury. There
In addition, Crown recommends that all mechanics also may be a danger of release
wear appropriate protective items, such as safety of harmful substances.
glasses, work gloves, and steel toed shoes, whenever Never smoke or bring flame
performing service or maintenance work on Crown near the battery.
equipment.
This gas remains in the battery cells long after charging
has stopped.
Battery
Warning! Risk of arcing!
Safety rules
Do not lay metallic or conduc-
tive objects on battery. Other-
wise arcing will result and
Warning! Risk of injury!
cause property damage.
Electrolyte contained in batter-
ies can cause severe personal z Do not allow dirt, cleaning solution or other foreign
injury or property damage if material to enter cells. Impurities in electrolyte has
coming in contact with eyes, a neutralizing effect reducing available charge.
skin, clothing or floor
Avoid any contact of electrolyte z If battery repair is planned, follow the battery man-
with eyes or skin ufacturer's instructions concerning repair practices
Wear protective clothing, such and procedures.
as, rubber apron, gloves, boots
and full face shield when per-
forming any maintenance on
batteries
6
SAFETY INSTRUCTIONS
Charging
Warning! Risk of property damage!

Caution! Risk of injury!
NEVER operate truck with an
undersized battery, otherwise Unauthorised component re-
the truck can be seriously dam- moval or improper maintenance
aged. can result in significant danger
Make certain battery used to the user.
meets weight, size and voltage Only qualified and experienced
requirements of truck (refer to personnel should perform
serial plate). maintenance and repair on bat-
teries.
z Make certain the charger being used matches the
voltage and amperage of the truck battery. This
voltage is listed on the truck serial plate. Warning! Risk of explosion!
Gas formed during charging is

Caution! Risk of injury! highly explosive and can cause
serious personal injury. There
Unauthorised component re- also may be a danger of release
moval or improper maintenance of harmful substances.
can result in significant danger Never smoke or bring flame
to the user. near the battery.
Only qualified and experienced
personnel should perform Never use a match or lighter. Battery fumes are explo-
maintenance and repair on bat- sive.
teries.
z Consult the charger manufacturer’s manual cover-
ing your charger for hints on operation and mainte-
Danger! Risk of accident!
nance.
Current flowing between battery
and charger can cause shock
hazard and result in serious in-
jury to you, the battery and
charger.
NEVER connect or disconnect
batteries to a charger while the
charger is “ON”.
Make sure the charger is “OFF”
before disconnecting or con-
necting batteries.
z Make certain battery used meets weight, size and

voltage requirements of truck (refer to serial plate).
NEVER operate truck with an undersized battery.
7
SAFETY INSTRUCTIONS
Battery removal Battery installation
Caution! Risk of short-circuit! Warning! Risk of injury!

Do not allow any metallic object A non-stable or rolling truck
to come in contact with the top may cause injury to you or oth-
of the battery cells. This may ers.
cause a short circuit when re- When installing a battery, move
moving, transporting a battery. truck to area intended for bat-
Use an insulator (such as ply- tery care.
wood, plastic caps) to cover the Floor must be level.
top of battery posts before and Turn keyswitch or toggle switch
during removal. to "off" position and remove
key.
When removing a battery, move truck to area intended
for battery care. Floor must be level.
Caution! Risk of short-circuit!
Turn keyswitch or toggle switch to "off" position and re-
Do not allow any metallic object
move key. Disconnect battery and lockout or tagout
to come in contact with the top
truck as described in Battery - Lockout/Tagout in this
of the battery cells. This may
section. Lower load engaging means completely.
cause a short circuit when re-
moving, transporting a battery.
Use an insulator (such as ply-
wood, plastic caps) to cover the
top of battery posts before and
during removal.
NEVER operate truck with an

undersized battery, otherwise
the truck can be seriously dam-
aged.
12024
Make certain battery used
meets weight, size and voltage
1 Wet cell battery
requirements of truck (refer to
2 Maintenance free battery
serial plate).
z Lockout or tagout truck as described in Battery -

Lockout/Tagout in this section.
8
SAFETY INSTRUCTIONS
Battery Lockout/Tagout When maintenance is performed and the batteries are
removed from the truck:
z remove the main power fuses,
z install a lockout device on the trucks battery con-

nector if possible,
z or if possible install a tag with a cable tie on the

trucks battery connector so it cannot be removed
easily warning that the truck is not available for op-
!
53
eration.
MS-2450-002
1 Key switch, OFF

2 Key
3 Key switch, ON
z Always turn key (2) switch to "off" (1), remove key

(2) and apply tag to steering pod with cable tie
warning others truck is being serviced.
When maintenance is performed and the batteries are

left in the truck:
z disconnect batteries,
z remove the main power fuses and
z install a commercially available lockout device on

battery connector.
9
SAFETY INSTRUCTIONS
Hydraulic When maintenance is to be performed on the hydraulic
system, make sure the hydraulic system is not under
Risk of accident: high pressure pressure:
Danger!
fluid!
z Move truck to a secure non traffic maintenance
Escaping fluid under pressure area with a level floor.
can penetrate the skin causing
serious injury. z No load on load tray (1).
Relieve pressure before discon-
necting hydraulic lines. z Completely lower load engaging means or, if re-
Tighten all connections before quired for maintenance, block truck at appropriate
applying pressure. height as described in Lifting and blocking,
Keep hands and body away page 11.
from pin holes which eject flu-
ids under high pressure. z Actuate the hydraulic switch to remove any hy-
Use a piece of cardboard or pa- draulic pressure that may be present.
per to search for leaks.
Do not use your hand. z Lockout or tagout truck as described in Battery
Any fluid injected into the skin under high pressure
should be considered as a serious medical emergency
despite an initial normal appearance of the skin. There
is a delayed onset of pain, and serious tissue damage
may occur. Medical attention should be sought imme-
diately by a specialist who has had experience with this
type of injury.
MS-2450-003
1 Load tray 2 Platform
10
SAFETY INSTRUCTIONS
Lifting and blocking z No load on load tray.
z Move vehicle to a secure non traffic maintenance z Lower platform completely.

area with a level floor.
z Lockout or tagout vehicle as described in Battery -
Tool Properties Value Crown Part

number
Capacity: 3620 kg (8000 lb) 122599

Hydraulik Jack Collapsed height (min.): 60 mm (2.25 in)
Raised height maximum: 400 mm (16 in)
Quantity 2
Hardwood blocks Dimensions: 100 x 100 x 762 mm
(4 x 4 x 30 in)
12027
1 Hydraulic jack 2 Hardwood block
11
SAFETY INSTRUCTIONS
Mast
&

)
)

Z
LH
9
QW
G
UR
HD
)
UK
YH
IW
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/H
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LJ
5
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5

12028
1 Straps 6 Second Stage Mast

2 Platform 7 Chassis
3 Third Stage Mast 8 Hardwood Block
4 Part of Third Stage Mast 9 Clamping Tool
5 Lifting Tool
12
SAFETY INSTRUCTIONS
z Move vehicle to a secure non traffic maintenance z Clamp hardwood blocks (8) to chassis (7), lower
area with a level floor. platform (2).
z Raise platform (2) to height necessary. z Disconnect electrical and chain connections nec-
essary to remove platform (2), third stage mast (3)
z Block the second stage mast (6) and platform (2) and second stage mast (6).
using the appropriate length and size hardwood
blocks (8). z Remove guides and shims necessary to remove
platform (2), third stage mast (3) and second stage
mast (6).
Tool Dimensions
z Insert lifting tool (5) into top of third stage mast (3)
100 x 100 mm [4 x 4 in] to assist in removing third stage mast (3).
Hardwood blocks
50 x 100 mm [2 x 4 in])
z Lockout or tagout vehicle as described in Battery -
13
SAFETY INSTRUCTIONS
Capacitance z Move truck to a secure non traffic maintenance
area with a level floor.
Capacitance voltage is present in the traction motor
controller. When performing maintenance which may z Lockout or tagout truck as described in Battery -
permit contact with the bus bars and associated power Lockout/Tagout in this section.
cables, discharge the capacitors.
z Place a minimum 100 Ω, 2 W resistor between the
B+ and B- terminals of the controller for three or
more seconds.
12033
14
INTRODUCTION
Printed in Germany
15
INTRODUCTION
Notice:
Printed in Germany
16
INTRODUCTION
This manual is intended for the service mechanic who Choice of dash number depends on language. When
is seeking information about maintenance. ordering, refer to chart below and complete the part
number the correct dash number
It contains a section on troubleshooting which will ena-
.
ble a qualified mechanic to locate and solve problems

which may occur. Dash Language Dash Language
number number
Operator instructions -001 German -004 Dutch

-002 French -005 Italian
Information -003 Spanish -006 English
This manual does not contain
operator instructions. Operator This manual is arranged by major sections. The first
part of the Control Number, found in the footer of each
instructions in booklet form are
page, denotes the section in which a particular form will
sent with each vehicle. be located. The section descriptions are as follows:
Additional copies can be ordered if required. These

booklets are for you and your personnel to insure years Section Description
of safe, trouble free operation.
M1 Lubrication and Adjustments
Service training M2 Hydraulics
M3 Drive Unit
Complete Service Training is available to the mechanic
upon request. M4 Electrical
M5 Brake
Publications M6 Not Used
M7 Mast
Copies of publications can be obtained from your
M8 Cylinder
Crown Dealer:
Crown M9 Platform
Kronstadter Straße 11
M10 Glossary
81677 München,
Deutschland DIA Wiring Diagrams
Phone: (089) 930 02 – 0,
Fax: (089) 930 02 – 133, crown.com
or from
A Division of Crown Equipment Pty Ltd.
Long & Cooper Streets
Smithfield, N.S.W. 2164
Sydney, Australia
Phone: (61) 29 604 6000
Fax: (61) 29 609 2787
crown.com
WAVE 50 10/2005 • Printed in Germany 22450
02 Rev. 10/04
17
INTRODUCTION
Data plate From these two numbers the vehicle model, series, se-
ries updates, vehicle size and specific vehicle data can
The data plate is located on the lower rear section of be determined. The following will explain the model
the third stage mast in the operator compartment and and vehicle data numbering system.
includes a model number and a vehicle data number.
6982-01
Model number example
1 Image generator – Work Assist Vehicle

2 Series update: Significant change(s) to the product that
would not merit a new series number (generation)
3 Version: Characteristic that distinguishes vehicle from other
versions
4 Lift height: 2135 mm (84 in) or 2995 mm (118 in)

MS-2450-006
22450 WAVE 50 10/2005 • Printed in Germany
02 Rev. 10/04
18
INTRODUCTION
Vehicle data number example You may simply provide this number to your dealer, or
use the following breakdown if selecting your own part
The vehicle data number provides you and your dealer numbers or service information from this manual.
with a wealth of information to ensure the selection of
proper parts for your vehicle.

MS-2450-007
1 Work Assist Vehicle 9 Wheel Color

2 Issue 10 Alarms
3 Truck Version 11 Meter
4 Lift height 12 Strobe
5 Vehicle 13 Storage
6 Batteries 14 Aisle Guide
7 Battery Charger 15 System Controller
8 Color 16 Language Code
WAVE 50 10/2005 • Printed in Germany 22450
02 Rev. 10/04
19
INTRODUCTION
Data number information

Information Meaning
Information Meaning – = No Strobe

Strobe 1 = Strobe
84 = 2135mm (84 in)
Lift height
118 = 2995mm (118 in) – = No Storage
– = Standard Storage 1 = One Pocket
Vehicle C = Custom 2 = Two Pockets
S = Special -- = No Guidance
Aisle Guide
1 = Wet 160 A 35 = Actual Width
Batteries 2 = Wet 205 – = No Handset
3 = Maintenance Free 195 A System Controller
1 = Handset
1 = 15 A A = French
Battery Charger
2 = 25 A B = German
1 = Maui Yellow C = British English
Language code
Color 2 = Seafoam Green D = Spanish
3 = Alpine White E = Italian
F = Dutch
1 = Yellow
Wheel Color
2 = Black
A = Forward
B = Reverse
C = Lift
D = Lower
E = Forward Reverse
F = Forward Lift
H = Forward Lower
I = Reverse Lift
Alarm
J = Reverse Lower
K = Lift Lower
L = Forward Reverse Lift
M = Forward Reverse Lower
N = Reverse Lift Lower
O = Forward Lift Lower
P = Forward Reverse Lift, Lower
Q = None
Meter HM = Hour Meter
22450 WAVE 50 10/2005 • Printed in Germany
02 Rev. 10/04
20
LUBRICATION & ADJUSTMENT
Printed in Germany
21
Notice:
Printed in Germany
22
Maintenance program
Maintenance program Before performing maintenance to any unit, it should

be taken to an area set aside for maintenance or a sec-
tion where there is adequate space to perform required
To obtain maximum life of any commercial equipment, work. This is a must to insure the safety of others and
a well planned maintenance program (PM), performed to insure that proper maintenance is performed to the
by qualified technical personnel should be followed. In unit.
conjunction with, and an integral part of, any planned
maintenance program should be daily operator input. If desired, padded packs of this checklist are available
Operator involvement can greatly reduce vehicle down through your Crown dealer.
time, assist in determining planned maintenance (PM)
schedules and ultimately save money. For these rea-
sons, Crown recommends a checklist similar to the Op-
erators Daily Checklist shown below.
7102S-01
WAVE 50 10/2005 • Printed in Germany M1-2450
01 Rev. 3/01
23
Lubricants and maintenance products
Lubricants and maintenance

products
The following is a list of lubricants and maintenance
products recommended when doing Planned Mainte-
nance on Crown vehicles.
Chart 1: Lubricant and Fluid
Type of lubricant Brand name Manufacturer
A. Gear Oil Lubriplate SPO-255 Fiske Bros. Refining Co.

B. Grease (Multipurpose) Union Unoba EP No. 2 Union 76 Co.
Retinax Aa Shell
LM Greasea Burmah Castrol
C. Hydraulic Oil Mobil DTE 24 Mobil Oil Co.

Union Unax AW ISO 32a Union 76 Co.
Tellus 32 Shell
Hyspin AWS 32a Burmah Castrol
Mobil AW32 Mobil Oil Co.
Sohio Energol HLP32 Sohio
D. Chain and Steel Cable Fluid Lubriplate Chain and Steel Cable Fluid Fiske Bros. Refining Co.
a. Denotes allowable substitutes, contact factory if unavailable.
Chart 2: Lubricant Identificaton
Type of lubricant Part number Package quantity
A. Gear Oil 063002-004 0.95 l

B. Grease (Multipurpose) 063002-024 0.5 g
C. Hydraulic Oil 063001-001 3.78 l
D. Chain and Steel Cable Fluid 063001-009 0.49 g
M1-2450 WAVE 50 10/2005 • Printed in Germany
01 Rev. 3/01
24
Component Accessibility
Component Accessibility Refer to the illustrations in this section as an aid in lo-

cating parts that require attention.
For regular maintenance, access to various vehicle

components is accomplished by removing covers or Information
panels. Make sure battery connectors
are disconnected.
The following is a general explanation of which cover,
panel, etc. that must be removed to allow for the most
efficient access when performing service and/or main-
tenance to components.

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MS-2450-008
1 Load Deck 4 Chassis

2 Contactor Panel 5 Service Panel
3 Rear Chassis Cover
01 Rev. 3/01
25
Chassis – Emergency Disconnect Contactor (EDS)

– horn (HN),
Load Deck (1) – travel alarm (ALM) (optional),

– fuses F2 and F3,
z Lift the load deck (1) at corners to remove it.
– connector CA801,
z Components located under the load deck: – filter block (SB81),
– lift pump (M3), – tilt sensor (TLTS) and
– hydraulic accumulator, – suppressor blocks (SB82 and SB83)
– solenoid valve (SV1),
– hydraulic reservoir and velocity fuse, Rear Chassis Cover (3)
– batteries,
z To remove the rear chassis cover (3), raise plat-
– controller assembly (MRC), form.
– contactor panel (2),
z Remove seven screws.
– battery charger,
z Lift off of vehicle.
– service panel (5),
– terminal boards TB201, TB202 and Components located under the rear chassis cover (3):
– diode block. – chain slack switches (CHSL and CHSR),
– lift chain anchor,
Contactor Panel (2) – left and right drive motor assemblies i.e.; mo-
tor(s) (M1 [CA601] left and M2 [CA602] right),
z To remove contactor panel (2) from vehicle, re-
– gear box and brake (CA603 and CA604 left
move two nuts and lockwashers securing the con-
and CA605 and CA606 right),
tactor panel (2) to chassis (4).
– left front/rear motor cover switches (FRMCS
z Disconnect electrical connections (CA801). and FLMCS),
– right front/rear motor cover switches (RRMCS
Components located on contactor panel (2):
and RLMCS).
01 Rev. 3/01
26
Service Panel (5) MRC Controller
z To remove the service panel (5) on front of vehicle, z To remove MRC controller, remove two screws.
tilt assembly down.
z Tilt out controller.
z Remove two screws.
z Remove six mounting screws, wiring harness
z Disconnect: (CA401) and power cables to remove controller
from mounting bracket.
– wiring harness (CA403),
– battery charger LED connector
Battery Charger
– charger AC connector (CA404).
z To remove battery charger, remove the four
Components located on service panel (5):
screws.
– hour meter (HM),
z Disconnect the DC and AC power cords, CA404
– fuse (F1),
and CA407.
– chassis emergency disconnect switch (EDS2),
Components located on battery charger are:
– push/drive switch (DTS),
– manual reset circuit breaker
– front strobe light (CHSLF) (optional),
– status lights and switch to select which type of
– circuit board that has LED's showing status of
battery is being charged i.e.: wet cell/sealed.
battery charging cycle,
– elevation control switch (ECS),
– emergency raise/lower switch (ERLS).
01 Rev. 3/01
27
Platform/Mast third Stage

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MS-2450-009
1 Yoke Assembly 6 Lift Chain Anchor Point Acces Cover

2 Steering Control Pod 7 Load Tray
3 Foot Brake Switches 8 Platform
4 Gate Switches 9 Traction Control Pod
5 Mast Height Switches 10 Mast Cap
01 Rev. 3/01
28
Steering Control Pod (2) – horn switch (HN)
– high speed switch (HSS)
z To remove steering control pod (2) remove the two
hex-head screws and two torx-head screws. – presence override switch (PORS)
– right hand presence sensors (RHS)
z Disconnect CA501 and CA701.
Components located on steering control pod (2): Mast Cap (10)

– steering potentiometer (POT1)
z Remove two screws that secure mast cap (10) to
– Curtis display CAN board expose yoke assembly (1).
– key switch (KYS)
– left hand presence sensors (LHS) Floorboard
z Remove four screws that secure access cover (6) z To remove floorboard, disconnect CA303.
on front of third stage mast to expose lift chain an-
chor point. z Push floorboard up and lift out.
z Remove two screws that secure cover on mast Components located on floorboard:
height switches ((5) RCS, HTS20 and CA304) on
– left and right foot brake switches ((3) DMSL
left side of platform (8) near bottom of third stage
and DMSR)
mast.
– Terminal boards TB301 and TB302 along with
diode block DB11
Traction Control Pod (9)
z To remove traction control pod (9) remove the two Gates

hex-head screws and two torx-head screws.
z Remove four screws that secure two gate switch
z Disconnect CA502 and CA702. covers on the bottom of the left and right gates to
expose gate switches (4).
Components located on traction control pod (9):
Components located on gates are:
– traction potentiometer (POT2)
– gate closed switch left (GCSL)
– emergency disconnect switch (EDS1)
– gate open switch left (GOSL)
– raise switch (RAS1)
– gate closed switch right (GCSR)
– lower switch (LOS1)
– gate open switch right (GOSR)
01 Rev. 3/01
29
Lubrication
Lubrication High grade lubricants and fluids should be used.

Sources of these lubricants may be from almost any of
the oil companies. Those listed on chart 1-1 are typical
The following information is intended to provide guide- and any lubricant with equal specifications may be
lines for proper lubrication intervals as called out in the used.
lubrication chart. However, some operating conditions
will require more frequent checks and lubrication than
listed. For example, applications with excessive dust or Information
moisture will require modification of the schedule to fit Use Planned Maintenance In-
that particular application.
spection Reports as required to
record and assure maintenance
checks.
01 Rev. 3/01
30
Lubrication
Notice:
31
Lubrication
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MS-2450-010
01 Rev. 3/01
32
Lubrication
Chart 3: Lubrication chart
Index Component Lub. Quantity 90 days 180 days 270 days 360 days
type
150 h 300 h 450 h 600 h
L-1 Drive Unit - Left A 150-175 ml 1st change change
L-2 Drive Unit - A 150-175 ml 1st change change

Right
L-3 Front Axle B As required Lube
L-4 Top 100 mm B As required Lube
Last
L-5 Aisle Guide B As required Lube
Rollers - Left
L-6 Aisle Guide B As required Lube
Rollers - Right
L-7 Hydraulik C 2.8 l 1st change change
Reservoir
L-8 Lift Chain D As required Lube
See Chart 2 for Lubricant type designation explanation. Lubrication intervals must be changed to a frequency
that will minimize wear on moving shafts and parts on
vehicles used in less desirable operating conditions.
Information
Hours are based on traction
hours which is accessible by
using Curtis handset.
01 Rev. 3/01
33
Lubrication
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MS-2450-011
01 Rev. 3/01
34
Lubrication
Chart 4: Inspection and Adjustment - Chassis Front
Index Component 90 days 180 days 270 days 360 days
150 h 300 h 450 h 600 h
I-1 Electrical i.e.: Connectors, Cables and Wiring Check

I-2 Front Axle and Casters Check
I-3 Wheels, Front and 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 and 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
I-16 Tilt Sensor i.e.: Broken Springs, Wiring,Verify
Check
Bubble is Centered
Refer to appropriate section of service manual for ad-

ditional information concerning inspection and/or ad-
justment.
Information
01 Rev. 3/01
35
Lubrication
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MS-2450-012
01 Rev. 3/01
36
Lubrication
Chart 5: Inspection and Adjustment - Chassis Rear
150 h 300 h 450 h 600 h

I-2 Drive Unit - Left (Motor, Gearbox and Brake) Check
I-3 Drive Unit - Right (Motor, Gearbox and Brake) Check
I-4 Chain Slack Switches (CHSL and CHSR) Check
I-5 Lift Chain Anchor Point Check
I-6 Motor Cover Switches (FLMCS and RLMCS) Check
I-7 Motor Cover Switches (FRMCS and RRMCS) Check
I-8 Rail Guidance Rollers - Left (Optional) Check
I-9 Lift Cylinder i.e.: For Cracks, Leakage and Se-
Check
cure Mounting to Vehicle
I-10 Rail Guidance Rollers - Right (Optional) Check
I-11 Rear Chassis Cover in Place and Secure Check
I-12 Chassis Springs i.e.: Broken, Missing Check
Refer to appropriate section of service manual for

additional information concerning inspection and/or
adjustment.
Information
01 Rev. 3/01
37
Lubrication
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MS-2450-013
01 Rev. 3/01
38
Lubrication
Chart 6: Inspection and Adjustment - Platform
150 h 300 h 450 h 600 h

I-2 Traction Pod (POT2, HN, RAS1, LOS1, EDS1,
Check
HSS, RHS and PORS)
I-3 Steering Pod (POT1, KYS and LHS) Check
I-4 Platform Padding For Wear and Tear Check
I-5 Floorboard Mat For Wear, Tear and Missing Check
I-6 Yoke For Wear and Cracks Check
I-7 Load Tray For Damage, Secure to Vehicle Check
I-8 3rd Stage Mast Lift Chain Anchor Point Check
I-9 Dynamic Cable Tension Area Check
I-10 Lift Chain For Tension, Wear and Broken/
Check
Cracked Links
I-11 Lift Cylinder For Leaks and Cracks Check
I-12 Foot Brake Switches (DMSL and DMSR) Check
I-13 Mast Lift Height Switches (RC3 and HTS20) Check
I-14 Left and Right Platform Gates For Operation Check
I-15 Left and Right Platform Switches (GOSL,
Check
GCSL, GOSR and GCSR)
I-16 Platform Springs For Cracked and Missing Check
I-17 Left and Right Bolsters For Cracks and Secure
Refer to appropriate section of service manual for ad-

ditional information concerning inspection and/or ad-
justment.
Information
01 Rev. 3/01
39
Torque Values
Torque Values Torque Chart – Standard Screws/Bolts
Dry torque requirements are specified in the chart be-

Standard Screws/Bolts low.
Torque requirements specified in the maintenance

sections of this manual take precedence over torque
requirements listed in the following chart.
Screw Grade 5 Grade 8

diameter
Nm ft.lb Nm ft.lb
1/4 in 12 ± 4 9±3 18 ± 5 13 ± 4
6155 5/16 in 24 ± 6 18 ± 5 34 ± 7 25 ± 5
3/8 in 43 ± 6 32 ± 5 65 ± 13 48 ± 10
Grade
7/16 in 67 ± 13 50 ± 10 102 ± 13 75 ± 10
All Crown vehicles are manufactured with SAE-grade 5 1/2 in 101 ± 13 75 ± 10 152 ± 20 112 ± 15
or better screws and bolts. Instances do occur when
SAE-grade 5 screws/bolts are manufactured un-
marked. Even though a fastener is unmarked, Crown
uses nothing less than SAE-grade 5 fasteners. When
an unmarked fastener requires replacement, replace
with a SAE-grade 5 fastener. Refer to the chart below
to identify grade.
Grade Mark- Specifica- Material

ing tion
SAE-Grade 2 Low Carbon Steel
SAE-Grade 5 Medium Carbon Steel

Quenched and Tem-
pered.
SAE-Grade 8 Medium Carbon Alloy

Steel, Quenched and
Tempered.
01 Rev. 3/01
40
Torque Values
Self Locking Screw/Nuts Grade
All self locking fasteners are SAE-grade 5 or better.

Grade cannot be determined by visual inspection.
Crown replacements are recommended since quality is
established and proven.
Torque Chart – Self Locking Screws/Nuts
Dry torque requirements are specified in the chart be-

low.
6156 Torque requirements specified in the maintenance

sections of this manual take precedence over torque
Self locking screws/nuts are used to secure many com- requirements listed in the following chart.
ponents. They are one-piece, all metal and lock when
seated. These screws/nuts do not require lockwashers
and eliminate separate screw, lockwasher and nut Screw diameter Torque
combinations.
Vehicles have been thoroughly tested and evaluated Nm ft.lb

utilizing self locking fasteners. Do not replace a self
locking screw/nut with a standard screw/nut and lock- 1/4 in 19 ± 4 14 ± 3
washer. 5/16 in 28 ± 6 21 ± 5
3/8 in 58 ± 6 43 ± 5
7/16 in 88 ± 13 65 ± 10
1/2 in 129 ± 13 95 ± 10
01 Rev. 3/01
41
Notice:
Printed in Germany
42
HYDRAULIC SYSTEM
Printed in Germany
43
HYDRAULIC SYSTEM
Notice:
Printed in Germany
44
HYDRAULIC SYSTEM
Hydraulic schematic symbols
Hydraulic schematic symbols
Symbol Meaning Symbol Meaning
Vented reservoir with lines Electric motor unidirectional

above fluid level single speed

Vented reservoir with lines Hydraulic pump fixed dis-

below fluid level placement unidirectional
Filter or strainer Spring (Bias to normal de-en-

ergised position)
Hydraulic line (plumbing , may Solenoid single coil or winding

be tubing, hose or flow pas-
sage in manifold) with full flow
Pilot or drain line, limited flow Component enclosure mani-

fold block
Lines crossing Resistor orifice throttle (ad-

justable)
Lines connected Resistor orifice throttle
Plugged port (test port) Relief valve adjustable
Accumulator, gas charged, di- Check valve

aphram type
01 Rev. 3/01
45
HYDRAULIC SYSTEM
Functional Description
MS-2450-014
1 Motor M3 6 Lift Cylinder

2 Accumulator 7 Hose
4 Solenoid Valve SV1 8 Fill Cap
5 Manual Lowering Valve
The hydraulic system is powered by a pump and motor Reservoir

assembly incorporating a gear type pump. This pump
supplies oil flow for the lift function. The maximum
With the lift cylinder (6) in the fully lowered position and
pressure of 13.8 MPa (2000 psi) for 2135 mm (84 in)
after all air has been bled from the hydraulic system, fill
lift height and 20.7 MPa (3000 psi) for 2995 mm
reservoir so that the oil level is at the "full" mark on the
(118 in) lift height is limited by an integral relief valve.
reservoir sight gauge. The total capacity of the hydrau-
The following is a general description of the system
shown below. lic system at this level should be approximately 2.8 l
(3 qt).
When the "lift" button is pressed, the pump motor M3
(1) is energized which in turn drives the lift pump. The Hydraulic Oils
pump draws hydraulic oil from the reservoir and directs
pressurized oil through an internal check valve to the
lift cylinder (6). When the lift cylinder (6) is fully ex- Use a good grade of hydraulic oil as recommended in
tended, the lift limit switch is actuated shutting off the the Lubricant and Fluid Chart located in the M1.0 Sec-
lift motor. tion of this manual.
When the "lower" button is pressed, the solenoid valve

SV1 (4) is energized. This allows the flow of hydraulic
oil to travel from the lift cylinder (6) through the flow
control valve back to the reservoir.
04 Rev. 7/04
46
HYDRAULIC SYSTEM
Manual Lowering To stop lowering the platform or return to normal oper-

ation:
In the event of an electrical malfunction, solenoid coil z Push button (B) of the manual lowering valve (5) in,
failure, etc., the platform can be lowered using the twist clockwise 180° and release.
manual lowering valve (5).
Warning! Risk of injury!

Accumulator Operation
By lowering the platform you The accumulator (2) is used as a shock absorber for
may cause injury to yourself the hydraulic system. If the platform is stopped sud-
and others or severely damage denly, the change in oil flow exerts pressure on the hy-
the truck components. draulic system. The accumulator (2) absorbs this oil
Before using the manual lower- pressure change by using the gas pressurized bladder
ing valve, make certain all peo- located within the accumulator (2). The bladder acts as
ple, including yourself, are clear a pillow to the pressurized oil, cushioning the applied
of the platform and load tray. pressure within the hydraulic circuit.
Warn the operator to stay com-
pletely inside the platform rails. The typical symptom of a bad or de-pressurized accu-
Stop lowering immediately if the mulator (2) is abrupt starting and stopping of the plat-
chains become slack, or any form during lift or lower.
part of the platform gets caught.
To lower the platform:
z Push button (A) of the manual lowering valve (5) in,

twist counterclockwise 180° and release.
In this position the manual lowering valve (5) will re-

main open.
04 Rev. 7/04
47
HYDRAULIC SYSTEM
Hydraulic Lines and Fittings

Danger! Risk of accident: high pressure
z Blow air through all hose and lines to remove loose fluid!
particles before installing. Escaping fluid under pressure
can penetrate the skin causing
Any rubber hose with wire braid inner construction and serious injury.
any lines which have been collapsed or kinked are per- Relieve pressure before discon-
manently damaged. necting hydraulic lines.
Tighten all connections before
z Replace all rubber hoses and lines even if the dam- applying pressure.
age is not externally visible. Keep hands and body away
from pin holes which eject flu-
z Flexible hose (7) must be replaced if it collapses in ids under high pressure.
normal operating position. Use a piece of cardboard or pa-
per to search for leaks.
z Clear any surface or edge of all hoses and lines, Do not use your hand.
which will cause damaging wear and cuts, or on
which they can become caught. Any fluid injected into the skin under high pressure
should be considered as a serious medical emergency
z All connections are to be leak free. despite an initial normal appearance of the skin. There
is a delayed onset of pain, and serious tissue damage
may occur. Medical attention should be sought imme-
diately by a specialist who has had experience with this
type of injury.
04 Rev. 7/04
48
HYDRAULIC SYSTEM
Lift Relief Valve Setting This will allow cylinder stop to bottom out for relief valve
setting.
The relief valve on the hydraulic unit comes factory set z In order to lift vehicle during adjustment, connect
at 13.8 MPa (2000 psi) for 2135 mm (84 in) lift height batteries or plug an alternate 24 V source into grey
and 20.7 MPa (3000 psi) for 2995 mm (118 in) lift connector attached to vehicle.
height. In most cases this should not require adjust-
ment during life of unit. z Through service panel fully raise empty platform
until cylinder bottoms out.
If for some reason it would require adjustment or re-
placement, perform the following procedure: z Attach a current clamp or current monitoring de-
vice to the hydraulic lift motor.
Information Sensitive Adjustment
z With cylinder bottomed out actuate service panel
Perform maintenance only with raise switch which will cause oil pressure to build
hydraulic unit at ambient tem- and activate relief valve.
perature.
During this time current measurement should be be-
z Fully lower platform. tween 105 to 135 A.
z Disconnect battery. z Tighten the adjustment screw to increase amper-

age. Loosen the adjustment screw to decrease
z Remove batteries on relief valve side of vehicle. amperage. Once range is achieved adjustment is
complete
z Remove hex cover of relief valve to expose adjust-
ment screw or relief valve removal. z Replace hex cover, batteries, height switch and
floorboard.
z Replace parts as required and reassemble.
z Remove platform floorboard and height switch as-

sembly from bracket so lift cutout switch does not
function.
04 Rev. 7/04
49
HYDRAULIC SYSTEM
Accumulator
Accumulator The accumulator (1) is used as a shock absorber for

the hydraulic system. If the platform is stopped sud-
denly, the change in oil flow exerts pressure on the hy-
draulic system. The accumulator (1) absorbs this oil
pressure change by using the gas pressurized bladder
located within the accumulator (1). The bladder acts as
a pillow to the pressurized oil, cushioning the applied
pressure within the hydraulic circuit.
Use an inert gas, such as Nitrogen for precharging or

topping off of accumulators (1). Size "T" bottle dry ni-
trogen, 8.5 m3 (300 ft3), 17.9 MPa (2600 psi) is recom-
mended.
Information
Accumulator is non-rechargea-
ble on 2135 mm (84 in) and
2995 mm (118 in) lift height ve-
hicles.
Warning! Risk of explosion!
MS-2450-015 Never use oxygen as a charging

agent for accumulators.
1 Accumulator Use only dry nitrogen as a
2 Swivel Nut charging agent for accumula-
tors.
3 Gas Valve
If the gas pressure in the nitro-
4 Gage
gen bottle is higher than the
5 Nitrogen Bottle maximum operating pressure of
6 Bottle Valve the accumulator, a gas pressure
7 Chuck handle reducing valve must be used.
8 Bleeder Valve
Crown can supply you with a 103623-004 Accumulator
Charging Tool, designed for charging and testing blad-
der and/or diaphragm type nitrogen charged accumu-
lators.
04 Rev. 7/04
50
HYDRAULIC SYSTEM
Accumulator
Precharging z Use the chuck handle (7) stem to tighten gas valve
(3) in accumulator (1) to 11 Nm (8 ft.lb).
z Lower platform completely.
Caution! Gas under pressure!
z Turn key switch Off, disconnect battery pack.
When gas pressure is released
z Remove vehicle load deck and locate the hydraulic from nitrogen bottle hose will
unit. cool down and consequently
stiffen.
z Remove dust cap from accumulator gas valve (3). Do not loop or twist hose. It
could be damaged.
z Use thread sealing and lubricating compound on
pipe threads of gage (4). z If desired precharge pressure is exceeded, make
sure nitrogen bottle valve (6) is closed, then open
z Attach one end of charging hose to the nitrogen bleeder valve (8) slightly, but only momentarily, to
bottle (5) and the other end to the accumulator reduce pressure.
charging tool.
Caution! Gas under pressure!
z Back chuck handle (7) all the way out before at-
taching assembly to accumulator gas valve (3). Never loosen swivel nut at-
tached to gas valve in accumu-
z Use wrench to tighten chuck handle swivel nut (2) lator without first backing
onto accumulator gas valve (3). Close bleeder chuck handle out all the way.
valve (8). Forces resulting from the gas
pressure may damage the
z Use chuck handle (7) to loosen gas valve (3) in ac- threads when the swivel nut is
cumulator (1). moved.
Do not reduce accumulator pre-
z Slowly open nitrogen bottle valve (6) to fill accumu- charge by depressing valve
lator (1). core. High pressure may rup-
ture rubber valve seat.
z Once the pointer on the gage (4) starts to deflect
unscrew the chuck handle (7) stem one full turn. z Once desired accumulator charge has been
achieved, remove accumulator charging tool.
The charge should be over a 2 to 4 min period to as-
sure a proper charge and to prevent damage to accu- z Check accumulator (1) for leaks with the use of
mulator (1). The proper precharge setting is 3105 kPa sealing spray or soapy water.
(450 psi ± 15 psi).
z Replace dust cap on accumulator (1).
z Shut off when gage (4) indicates proper charge.
z Reconnect battery and return vehicle to service.
04 Rev. 7/04
51
HYDRAULIC SYSTEM
Hydraulic Troubleshooting
Hydraulic Troubleshooting The ability to identify problems and proceed in solving

the problem grows with experience.
The following Hydraulics Troubleshooting Chart con- The following chart contains symptom, probable cause
tains general information necessary to effectively solve and remedy. The information is general in nature and a
the more common hydraulic problems. remedy may simply refer you to a maintenance section
that has more complete troubleshooting. Use the
z Know the system to the best of your ability. chart(s) carefully and completely. Do not make the sys-
tem more complicated than necessary.
z Understand the components and their function
within the system. z Do not overlook the simplest reason(s) for a hy-
draulic problem.
z Develop a systematic pattern to locate and solve
the various hydraulic problems that occur.
Information
Entries marked with (a), be sure
the vehicle has been performing
its normal duty cycle at this
time.
Symptom Probable cause Remedy
Introduction of air into pump Check reservoir oil level.

Check for proper oil viscosity.
Hydraulic oil foaming Check plumbing.
Water in oil Check reservoir.
Oil too thina Change to proper viscosity oil.
Hydraulic oil Oil contaminated Empty reservoir and fill with clean oil.
overheatinga Introduction of air into pump Check plumbing.
Oil level low Fill reservoir to proper level.
Blown lift fuse Replace lift fuse
Manual lowering valve actuated Refer to Manual Lowering, page 47.
Platform will not raise Mast assembly binding Inspect mast for damage or misalignment.
Failed lift contactor Replace lift contactor.
Lift motor or pump not operating Repair or replace pump and/or motor.
02 Rev. 3/01
52
HYDRAULIC SYSTEM
Velocity fuse actuated Check for severe oil leak.

Check for more than capacity load.
Flow control valve reset.
Raise slightly to reset velocity fuse.
Chain slack switch actuated Raise slightly to eliminate chain slack.
Platform will not lower Solenoid valve malfunction Repair or replace valve assembly
Motor cover switch actuated Clear/check for obstruction from/on motor
cover.
Binding in mast assembly Inspect mast & platform for damage, mis-
alignment, etc.
Failed Lower Solenoid Replace Lower Solenoid.
Flow control valve malfunction Cycle through lift/lower to free debris.
Line restriction Check plumbing.
Lowers too slow
Binding in mast assembly Inspect mast & platform for damage, mis-
alignment, etc.
Flow control valve malfunction Cycle through lift/lower to free debris.
Lowers too fast
External oil leak Check plumbing for leak(s).
No cushion during raise Accumulator malfunction Charge accumulator properly. Refer
or lower to accumulator information section,
page 50.
Relief valve not adjusted properly Adjust relief valve.
Mast binding Inspect mast for damage, misalignment,
Will not lift capacity load
etc.
Hydraulic component(s) malfunction Refer to hydraulic system, page 46.
Debris in solenoid valve Cycle through lift/lower to free possible de-
bris.
Platform drifts down
Lift cylinder packings leaking Refer to cylinder information section,
page 207.
Accumulator loses Accumulator valve leaking, cracked, de- Repair. Refer to accumulator mainte-
charge formed, etc. nance section, page 50.
Abnormal hydraulic oil External leak Check plumbing, cylinder, other hydraulic
usage components.
Exceeding capacity load Check load weight.
Worn or damaged pump and motor Inspect pump and motor. Repair or re-
Lift pump and motor
place.
overheatinga
Fluid level low Inspect fluid level. Fill system to proper
level. Refer to page 46.
02 Rev. 3/01
53
HYDRAULIC SYSTEM
Lift chains not adjusted properly Adjust chains.

Mast and/or platform binding Inspect mast and platform for damage,
wear, etc.
Failure of platform to
raise and lower Hydraulic component malfunction Inspect pump, motor, valve, cylinder, etc.
smoothly for damage, leaks, wear.
Accumulator malfunction Refer to section Accumulator, page 50.
Air trapped in cylinder Bleed.
a. Be sure the vehicle has been performing its normal duty cycle at this time.
02 Rev. 3/01
54
DRIVE UNIT
Printed in Germany
55
DRIVE UNIT
Notice:
Printed in Germany
56
DRIVE UNIT
Drive Unit Gearbox Lubrication

Caution! Risk of damage to the plastic
side panel!
Do not try to lift the vehicle if
jack is under the plastic side
panel. Make sure it is under the
the steel truck frame.
To check oil level:
z Raise and block platform using hardwood

block (17).
Danger! Risk of trapping and severing

limbs!
An unsecured mast and attach-
ments can sever limbs or even
cause fatal injuries. Always
MS-2450-017 block mast when working on ve-
hicle with mast in elevated posi-
17 Hardwood Block tion.
18 Hydraulic Jack P/N 122599
z Turn key switch off, remove load deck and discon-
nect batteries.
There is a right and left drive unit. Oil level in the gear-
box should be checked after 250 h or 60 days of serv-
ice. Gearbox oil should be changed after every 2000 h
or 12 months of service. To change oil, the gearbox
must be removed from the vehicle.
04 Rev. 3/01
57
DRIVE UNIT
MS-2450-016
04 Rev. 3/01
58
DRIVE UNIT
1 Access Cover 9 Screw

2 Access Cover 10 Gearbox
3 H Frame (3 pieces) 12 Shim Pad
6 Hub Cap 14 Oil Level Plug
7 Flange Nut 15 Breather Plug
8 Drive Wheel 16 Drain Plug
z Remove access covers (1, 2). z Attach "H" frame (3 pieces), (3) and access covers
(1, 2).
z Remove "H" frame (3 pieces), (3).
z Connect batteries.
z Remove oil level plug (14), oil should run out oil
level hole. If oil does not run out hole, remove z Raise platform slightly.
breather plug (15) and add Lubriplate SPO-255 oil
until it starts to run out the oil level hole. Replace oil z Remove hardwood block (17).
level plug (14) and breather plug (15). Clean up
any oil that may have run out. z Lower platform.
z Replace load deck.
04 Rev. 3/01
59
DRIVE UNIT
Gearbox Replacement
Gearbox Replacement z Remove three screws (9), holding drive unit to ve-
hicle.
z Raise and block platform using hardwood z Drive motor and brake can be removed from gear-
block (17). box (10) as a unit.
Danger! Risk of trapping and severing z Remove coupler from gearbox (10) if gearbox (10)
limbs! is being replaced. If the oil is going to be replaced
in the gearbox drain it using drain plug (16) located
at bottom of gearbox (10). Any shavings or sedi-
ment in gearbox (10) should not be disturbed so do
not turn it upside down.
block mast when working on ve-
z Install coupler, drive motor and brake on gearbox
tion.
(10).
z Turn key switch off, remove load deck and discon-
z If gearbox (10) is being replaced, remove shim pad
nect batteries.
(12) from old gearbox (10) and put on new unit.
z Place hydraulic jack P/N 122599 (18) at position
z Mount drive unit to vehicle and torque three
"A" making sure it is under the vehicle frame and
screws (9) to 60 Nm (45 ft.lb).
not directly under the plastic side panel. Raise side
of vehicle about 25 mm (1.0 in). Place a
z If gearbox (10) is new it should have oil in it, how-
50 x 100 x 305 mm (2 x 4 x 12 in) hardwood block
ever check level and add if required. If oil is being
under rear frame and lower jack (18). Rear wheel
changed in gearbox (10), add Lubriplate SPO-255
should be about 6 mm (0.25 in) off of floor.
oil thru breather plug (15) hole until it starts to run
out oil level hole. Replace oil level plug (14) and
z Remove access covers (1, 2).
breather plug (15). Clean up any oil that may have
run out.
z Remove "H" frame (3 pieces), (3).
z Mount drive wheel (8) on axle and torque flange
z Remove hub cap ( 6).
nut (7) to 135 Nm (100 ft.lb).
z Remove flange nut (7) in center of hub.
z Replace hub cap (6).
z Remove drive wheel (8) with bar type puller (if
z Install "H" frame (3 pieces),(3) on vehicle as shown
available) and woodruff key. If key is damaged re-
in illustration.
place it. If bar type puller is not available, a pry bar
may be used to work around the backside of the
z Mount access covers (1, 2).
drive hub to remove from tapered shaft of
gearbox (10). Do not pry on the tire, only on the
z Connect batteries, raise platform slightly, remove
steel part of the drive wheel (8).
hardwood block (17), lower platform and replace
load deck.
z Unplug connectors to drive motor and brake noting
wire locations.
z Run operational check on vehicle.
04 Rev. 3/01
60
DRIVE UNIT
Wheels
Wheels

%
$

MS-2450-018
1 Drive Wheel 7 Retaining Ring

2 Flange Nut 8 Hub Cap
3 Hub Cap 9 Hydraulic Jack P/N 122599
4 Woodruff Key 10 Hardwood Block
5 Bearing 11 Hardwood Block
6 Caster Wheel
05 Rev. 10/04
61
DRIVE UNIT
Wheels
Drive Wheel Replacement z Remove hub cap (3).
z Remove flange nut (2) in center of hub.

z Lower platform completely, turn key switch off, re-
move load deck and disconnect batteries. z Remove drive wheel (1) with bar type puller (if
available) and woodruff key (4). If key is damaged
z Refer to Illustration MS-2450-018. Place hydraulic replace it. If bar type puller is not available, a pry
jack P/N 122599 (9) at position "A" making sure bar may be used to work around the backside of
that it is under frame. the drive hub to remove from tapered shaft of gear-
box.
Caution! Risk of damage to the plastic
side panel! z Install replacement drive wheel (1).
z Install flange nut (2) and tighten to 135 Nm
(100 ft.lb).
z Replace hub cap (3).
z Place a 50 x 100 x 305 mm (2 x 4 x 12 in) hard-
z Jack vehicle up as before, remove hardwood
wood block (10) under the rear frame and lower
block (10).
hydraulic jack P/N 122599 (9). Vehicle will rest on
hardwood block (10) with drive wheel (1) about
z Lower and remove hydraulic jack P/N 122599 (9).
6 mm (0.25 in) off of floor.
z Connect batteries and replace load deck.
Warning! Risk of crushing!
The vehicle is only lifted for

maintenance purposes. It can
slip or move at any moment.
Do not put any part of your body
under the vehicle during this
procedure.
05 Rev. 10/04
62
DRIVE UNIT
Wheels
Caster Wheel Replacement z Remove hub cap (8) with a screwdriver by prying
behind the half circles located around outside edge
of hub cap (8).
z Lower platform completely, turn key switch off, re-
move load deck and disconnect batteries. z Remove retaining ring (7).
z Place hydraulic jack P/N 122599 (9) at position "B", z Remove caster wheel (6) and inspect bearings (5).
making sure that it is under frame.
z If they are not worn, remove from caster wheel (6)
Caution! Risk of damage to the plastic and press into new caster wheel (6). Do not put
side panel! pressure on inside bearing (5) race, only on out-
side bearing (5) race.
z Install new caster wheel (5) back on spindle and
replace retaining ring (7).
z Install hub cap (8).
z Place a 100 x 100 x 355 mm (4 x 4 x 14 in) hard-
wood block (11) under the frame between hydrau-
z Jack vehicle up as before, remove hardwood
lic jack P/N 122599 (9) and caster wheel (6) and
block (11).
lower hydraulic jack P/N 122599 (9). Vehicle will
rest on hardwood block (11).
z Lower and remove hydraulic jack P/N 122599 (9).
Warning! Risk of crushing! z Connect batteries and replace load deck.
The vehicle is only lifted for

maintenance purposes. It can
slip or move at any moment.
Do not put any part of your body
under the vehicle during this
procedure.
05 Rev. 10/04
63
DRIVE UNIT
Notice:
Printed in Germany
64
ELECTRICAL MAINTENANCE
Printed in Germany
65
Notice:
Printed in Germany
66
Before performing maintenance to the vehicle, move z Operator and vehicle interface to the control sys-
vehicle to an area set aside for maintenance or where tem is through switches, sensors, electronic key
there is adequate space to perform the required work. pad and potentiometers.
This is a must to insure the safety of others and to in-
sure that proper maintenance is performed. z Control system is microprocessor based with pro-
gram to provide specific outputs with predeter-
mined inputs from interface components.
Danger! Risk of serious injury!
Danger to personnel in the vi- z Individually controlled dual drive motors provide
cinity as long as the truck has forward and reverse travel, steering along with
power supply. service braking.
While servicing or testing the
truck it may start suddenly and z Steering input to control system is provided
accidentally (due to mistakes or through left hand controlled rocker mechanism
faults). People standing in the coupled to a potentiometer.
way of the truck could be fatally
injured. z Travel direction and speed is provided by a right
Be sure all wheels are chocked hand controlled twist grip coupled to a potentiome-
before proceeding. ter.
z Raise, lower and horn input is through right hand

controlled push buttons.
z Emergency electrical disconnect is accomplished
Battery is to be disconnected through an emergency disconnect contactor (ED).
whenever removing compo- The power tips of this contactor provide the power
nents from the truck. path between the battery and vehicle electrical
Proper grounding and anti- system. ED coil is controlled by a maintained con-
static measures should be ob- tact switch with a push button actuator. Each time
served to prevent static damage the push button is pressed, the switch contacts
to electronic components. change condition (open, closed), resetting and en-
If necessary to work on the vehi- ergizing the contactor.
cle with the battery connected
all jewelry should be removed z The control, drive and lift electrical circuits are indi-
i.e.: rings and watches, as to vidually protected by fuses.
prevent possible shock from
metal contacting electrical cir- z Control system troubleshooting is through service
cuits. codes which are displayed on a handset which is
plugged into the electrical system. Service codes
z Vehicle is powered by 24 V electrical system are also displayed in code through the display Bat-
through four maintenance free 6 V batteries con- tery Discharge Indicator lights.
nected in series.
02 Rev. 3/01
67
Component Accessability
Information
Platform Shown Partially Eleva-
Chassis (under load deck)
ted and Service Panel Open for
Illustration Purposes
z Lift load deck (1) from vehicle.
MS-2450-019
02 Rev. 3/01
68
1 Load Deck 12 Hour Meter (HM)

2 Emergency Disconnect Contactor (ED) 13 Push/Drive Switch (DTS)
3 Fuses FU-2 and FU-3 14 Emergency Raise/Lower Switch (ERLS)
4 Filter 15 Elevation Control (ECS)
5 Tilt Sensor (TLTS) 16 Emergency Disconnect Switch
6 Horn (HN) and Suppressor Block (SB82) 17 Fuse FU-1
7 Pump Motor (M3) 18 MRC Controller
8 Suppressor Block (SB21) 19 Batteries
9 Pump Contactor (P1) 20 Battery Disconnect
10 MRC1 DB22 21 Travel Alarm (AL)
11 Battery Charger 22 Suppressor (SB83)
02 Rev. 3/01
69
Chassis (under platform)
MS-2450-020
1 Rear Chassis Cover 5 Front/Rear Right Motor Cover Switch (FRMCS and RRMCS)
2 Traction Motor 6 Chain Slack Switch (CHSK and CHSR)
3 Electric Park Brake 7 Front/Rear Left Motor Cover Switch (FLMCS and RLMCS)
4 Actuator for Left/Right, Front/Rear Motor Cover Switch 8 Traction Motor (M1)
z Raise platform to height that would provide a com- z Remove mounting screws securing access covers
fortable working area and use hardwood blocks to in place and lift from vehicle.
support platform at this height.
02 Rev. 3/01
70
Steering Control Pod Traction Control Pod
MS-2450-021 MS-2450-022
1 Steering (POT1) 1 Emergency Disconnect (EDS1)

2 Display 2 High Speed Switch (HSS)
3 Electronic Key Pad 3 Presence Override Switch (PORS)
4 Key Switch (KYS) 4 Traction Pod (POT2)
5 Rail Pad 5 Rail Pad
6 Mounting Screw 6 Mounting Screw
7 Steering Pod 7 Horn Switch
8 Lower Switch (LOS1)
9 Raise Switch (RAS1)
z Remove rail pad (5).
z Remove mounting screws (6). z Remove rail pad (5).
z Pull steering pod (7) towards yourself to allow z Remove mounting screws (6).
connector to be disconnected.
z Pull traction pod (4) towards yourself to allow
z Pull steering pod (7) to exit restraint rail. connectors to be disconnected.
z Pull traction pod (4) to exit restraint rail.
02 Rev. 3/01
71
Platform Floor Components z Remove screws holding cover around mast in

place then lift from platform.
z Lift floorboard to allow connector to be discon-
nected then lift from platform.
MS-2450-023
1 Raise Cutout Switch (RCS) &Traction Cutout Switch (HTS20) 8 Floorboard

2 Terminal Board (TB301) 9 Foot Brake Switch Right (DMSR)
3 Diode Block (DB11) 10 Foot Brake Switch Left (DMSL)
4 Terminal Board (TB302) 11 Floorboard Mat
5 Gate Open/Closed Switch (GORS/GCRS) 12 Gate Switch Cover
6 Gate Switch Cover 13 Gate Open/Closed Switch (GOLS/GCLS)
7 Platform Strobe Lights (PLSLL and PLSLR)
02 Rev. 3/01
72
Switches
Switches 1 Front Right Motor Cover Switch (FRMCS)

2 Rear Right Motor Cover Switch (RRMCS)
3 Chain Slack Switch (CHSR2)
4 Chain Slack Switch (CHSL2)
5 Rear Left Motor Cover Switch (RLMCS)
6 Front Left Motor Cover Switch (FLMCS)
7 Chain Slack Switch (CHSL1)
8 Chain Slack Switch (CHSR1)

A Part of Chassis
B Part of Platform
CHSL1 Chain Slack Switch

CHSR1 Chain Slack Switch

• Used on 2995 mm (118 in) lift height only.

• Located on inside front of platform.
$ • Used to detect slack lift chain.
• No adjustment required, however, correct chain
adjustment is required for proper operation.
CHSL2 Chain Slack Switch
CHSR2 Chain Slack Switch
• Located in the base of the vehicle under the
platform.
% • Used to detect slack lift chain.
• No adjustment required, however, correct chain
adjustment is required for proper operation.
MS-2450-031
03 Rev. 10/04
73
Switches
MS-2450-027
1 Foot Brake Switch Left (DMSL)

2 Foot Brake Switch Right (DMSR)
DMSL Foot Brake Switch Left

DMSR Foot Brake Switch Right
• Located in floorboard of the platform. MS-2450-024
• Used to detect operators position on the vehicle.
1 Push/Drive Switch (DTS)
• No adjustment required.
2 Elevation Control (ECS)
3 Emergency Disconnect Switch (EDS2)
4 Emergency Raise/Lower Switch (ERLS)
DTS Push/Drive Switch

• Located on the service panel.
• Push position releases brake and disables drive
functions.
ECS Elevation Control Switch
• Used for emergency raise and lower functions in
the base position (also see ERLS).
ERLS Emergency Raise/Lower Switch (See illustra-
tion MS-2450-024)
• Allows for maintenance or emergency raise and
lower when switch ECS is in the base position.
03 Rev. 10/04
74
Switches
MS-2450-026
1 Adjustment Screw
2 Gate Open Switch Right (GOSR)
3 Gate Closed Switch Right (GCSR)
4 Gate Open Switch Left (GOSL)
5 Gate Closed Switch Left (GCSL)
MS-2450-030
See also illustration MS-2450-023.

1 Right Hand Presence Sensor (RHS)
2 High Speed Switch (HSS)
3 Presence Over Ride Switch (PORS)
GCSL Gate Closed Switch Left
4 Horn Switch (HNS)
GOSL Gate Open Switch Left
5 Lower Switch (LOS1)
• Located at lower left of platform gate.
6 Raise Switch (RAS1)
• Indicates open or closed safety gate.
7 Emergency Disconnect Switch (EDS1)
• Adjustment required to ensure switch actuates
in proper gate position.
EDS1 Emergency Disconnect Switch
GCSR Gate Closed Switch Right
• Located on the traction control pod.
GOSR Gate Open Switch Right
• Pushing button disconnects vehicle power.
• Located at lower right of platform gate.
• Indicates open or closed gate.
EDS2 Emergency Disconnect Switch
• Adjustment required to ensure switch actuates
in proper gate position.
• Pushing button disconnects vehicle power.
03 Rev. 10/04
75
Switches
HNS Horn Switch (See Illustration MS-2450-030) HTS20 510 mm (20 in) Height Switch
• Located on the traction control pod. • Located on lower left side of mast in platform.
• Used to sound horn. • Used to determine 510 mm +12.7/-25 mm (20 in
• No adjustment required. +0.50/-1.0 in) platform height.
HSS High Speed Switch • Adjustment required for vehicles with 2135 mm
(See Illustration MS-2450-030) (84 in) lift height. To adjust, rotate adjustment
• Located on the traction control pod. screw in one half revolution increments until
• Used to switch from limited speed to normal switch actuates properly (switch assembly must
speed operation. be removed from vehicle to rotate adjustment
• No adjustment required. screw).
HTS84 2135 mm (84 in) Height Switch
Used on 2995 mm (118 in) Lift Height Only (See Illus-
tration MS-2450-025)
• Located on back side of platform mast (facing
operator).
• Used to determine 2135 mm +12.7 or -25 mm
((84 in +0.50 or -1.0 in) platform height.
• Adjustment required for vehicles with 2995 mm
(118 in) lift height. To adjust, rotate adjustment
screw in one half revolution increments until
switch actuates properly (switch assembly must
be removed from vehicle to rotate adjustment
screw).
MS-2450-025
1 Adjustment Screw
2 Lift Height Switch Assembly (Side View)
3 Raise Cutout Switch (RCS) and Height Switch (HTS20,
HTS84)
03 Rev. 10/04
76
Switches
MS-2450-028 MS-2450-029
1 Left Hand Presence Sensor (LHS) 1 Electronic Key Pad

2 Main Key Switch (KYS) 2 Steering Control Pod
KYS Key Switch Electronic Key Pad

• Located on steering pod. • Located on steering control pod (2).
• Used to energize vehicle. • Used to energize vehicle.
• No adjustment required. • Can be programmed to store up to 200 Personal
Identification Numbers (PIN's).
• Allows multiple users, each with their own PIN.
• Replaces key and key switch.
03 Rev. 10/04
77
Switches
FLMCS Front Left Motor Cover Switch RAS1 Raise Switch
RLMCS Rear Left Motor Cover Switch (See Illustration MS-2450-030, page 75)
• Located on the traction control pod.
FRMCS Front Right Motor Cover Switch
• Used to raise platform.
RRMCS Rear Right Motor Cover Switch
(All switches see Illustrations MS-2450-020, page 70
and MS-2450-031, page 73) LHS Left Hand Presence Sensor
• Located under rear chassis cover, under plat- (See Illustration MS-2450-028, page 77)
form. RHS Right Hand Presence Sensor
• Disables lower/travel functions when activated. (See Illustration MS-2450-030, page 75)
• No adjustment required. • Located on the steering control pod.
LOS1 Lower Switch • Senses hand presence.
(See Illustration MS-2450-030, page 75) • No adjustment required.
• Located on the traction control pod. RCS Raise Cutout Switch
• Used to lower platform. (See Illustration MS-2450-025, page 76)
• No adjustment required. • Located on lower left side of mast in platform.
PORS Presence Over Ride Switch • Used to stop lift pump at full extended height.
(See Illustration MS-2450-030, page 75) • Adjustment required for vehicles with 2135 mm
• Located on the traction control pod. (84 in) lift height. To adjust, rotate adjustment
• Used to override presence sensors and limit per- screw in one half revolution increments until
formance. switch actuates properly (switch assembly must
• No adjustment required. be removed from vehicle to rotate adjustment
screw).
03 Rev. 10/04
78
Potentiometers
Potentiometers POT1 Steering Potentiometer Link-

age Adjustment
When the pot cam, connector arm to POT1 (6) assem-

bly and the rocker (1) are assembled and functionally
correct, the rocker (1) will freely rotate in both direc-
tions. The casting will be the only physical stop to pre-
vent the rocker (1) from rotating. Refer to Illustration
MS-2450-033.

MS-2450-032
1 Rocker
7 Steering Potentiometer POT1
POT1 Steering Potentiometer

• Located in steering control pod.
• Provides command signal to system controller
for steering function.
• When replaced or instructed by service codes,
potentiometer requires calibration. Reference
Controller Settings in this manual and perform MS-2450-033
Calibration 4, 5 and 6.
1 Rocker
2 Right Casting Stop
3 Mounting Screw
4 Swivel Ball Link
5 Left Casting Stop
6 Connector Arm to POT1
If the rocker (1) is unable to reach the stop of the cast-

ing, it is being halted by the internal stop of the pot
module, which is incorrect. Adjustment is needed to al-
low the rocker (1) to rotate freely. This can be accom-
plished by increasing or decreasing the length of the
connector arm to POT1 (6) assembly.
02 Rev. 3/01
79
Potentiometers
A. Unable to rotate rocker to the left casting stop: z Connect connector arm (6) to rocker (1).
z Remove mounting screw (3) that fastens connec- z Re-inspect rocker rotation. If only the casting pre-
tor arm (6) to the rocker (1). vents rocker (1) from rotating, no further adjust-
ment is needed. If not, connector arm (6) needs to
z The length of the connector arm (6) needs to to be be longer. See illustration below.
increased. Hold the steel connector arm (6) and ro-
tate the swivel ball link (4) counterclockwise one
revolution.
MS-2450-034
1 Rocker 5 Left Casting Stop

A No Gap B Gap Present
02 Rev. 3/01
80
Potentiometers
B. Unable to rotate rocker to the right casting stop: z Hold the steel connector arm (6) and rotate the
swivel ball link (4) clockwise one revolution.
z Remove screw that fastens connector arm (6) to
the rocker (1). z Connect connector arm (6) to rocker (1).
z The length of the connector arm (6) needs to be z Re-inspect rocker rotation. If only the casting pre-
decreased. vents rocker (1) from rotating, no further adjust-
ment is needed. If not, connector arm (6) needs to
be shorter. See illustration below.
MS-2450-036
1 Rocker 2 Right Casting Stop

A No Gap B Gap Present
POT2 Traction Potentiometer

• Located in traction control pod.
• Provides command signal to system controller
for traction function.
• When replaced or instructed by service codes,
potentiometer requires calibration. See "Control-
ler Settings" on page 109 and perform Calibra-
tion 1, 2 and 3 (page 116).
MS-2450-035
1 Traction Potentiometer POT2
02 Rev. 3/01
81
Fuses
Fuses
When a fuse fails, the associated circuitry should be
checked for short circuits before a new fuse is installed.
Never jumper a fuse. Attempting to bypass a fuse could
seriously damage associated circuitry. Always replace
fuse with the same type and rating as specified.
MS-2450-038
1 Contactor Panel
MS-2450-037 2 FU3
3 FU2
1 Service Panel
2 FU1
Fuse Location Circuit Type and Size Part Number
FU1 Service Panel Control ABC-15 A 094362-002

ACK-40 A
FU2 Contactor Panel Traction 076924-011
ECK-40 A
ACK-40 A
FU3 Contactor Panel Lift 076924-011
ECK-40 A
01 Rev. 3/01
82
Fuses
Notice:
83
Control Cables
Control Cables
2135 mm (84 in) Lift Height
MS-2450-039
04 Rev. 7/04
84
Control Cables
1 Fixation 15 Cable Clamp

2 Cover Plate 18 Mast Cap
3 End Cap 19 Hydraulic Hose
4 Screw 21 Nut
5 Flatwasher 22 Guide
6 Rubber Insert 23 Manual Lowering Valve
7 Part of Chassis 24 Lockwasher
8 Dynamic Cable
11 Tension Bracket M3 Hydraulic Pump Motor
14 Cotter Pin P1 Solenoid
Control Cable Re-tension z Tighten screw (4) until tension bracket (11) has
bottomed out against chassis (7).
Control cables are routed through the mast pulleys and
are kept seated by a tension device located in front of z Disconnect connectors CA101 and CA102, re-
the first stage mast on the chassis. After adjustment, move cable clamps (15) on either side of third
each control cable will have approximately 11.3 kg stage mast.
(25 lb) of pull. To obtain proper cable tension adjust as
follows: z Pull cables and plugs through holes in bottom right
and left hand sides of platform.
z Adjusting chain and platform height after tension-
ing control cables can induce stress or loosen ca- z Pull cables tight from bottom of platform mast.
bles. Ensure chains and platform height are ad-
justed properly prior to tensioning cable. z Feed cables back up through platform making sure
they are seated in guides at bottom of platform
z Raise platform and block using a hardwood block. mast.
z Turn key switch off. z Replace cable clamps (15) and plug into mating
connectors.
z Remove load deck from vehicle and disconnect
batteries. z Loosen screw (4) until cotter pin (14) bottoms out
on tension bracket (11).
z Disconnect connector CA303, for DMSR and
DMSL switches located below rear part of floor- z Replace floorboard, cover plate (2) on chassis (7)
board chassis, remove floorboard and cover plate and connect plug CA303 for DMSR and DMSL
(2) on chassis (7). switches.
z Connect batteries, replace load deck, unblock

mast and lower.
04 Rev. 7/04
85
Control Cables
Cable Replacement z Remove control cable connections from TB201,
TB202 or both, depending on which cable or ca-
If a control cable needs to be replaced the following bles are going to be replaced. Note wire locations
procedure should be followed . on terminal blocks. If one cable is being replaced
due to wear, it would be best to replace both con-
z Ensure chains and platform height are adjusted trol cables.
properly prior to tensioning cable.
z Relieve all tension on control cables by taking cot-
z Raise platform and block using a hardwood block. ter pin (14), screw (4) and flatwashers (5) from ten-
sioning device.
Danger! Risk of trapping and severing z Disconnect cables CA101 and CA102 at platform
limbs! end and remove cable clamps (15).
ments can sever limbs or even z Pull cable, plug end, down through floorboard be-
cause fatal injuries. Always side platform mast.
hicle with mast in elevated posi- z Remove guides (22) from bottom of platform mast.
tion.
z Pull both cables out of chassis mast at tensioning
z Turn key switch off, remove load deck and discon- device end about 240 mm (9.5 in) or until plugs
nect batteries. CA101 and CA102 are even with bottom of plat-
form mast. Do not put any strain on plugs by trying
z Remove mast cap (18) on platform mast from ve- to pull cables out too far.
hicle.
z Remove strain relief end cap (3) and rubber insert
z Disconnect connector CA303 for DMSR and from cable that is being replaced. Do not loosen
DMSL switches located below rear part of floor- strain relief at all on cable that is not being re-
board chassis, remove floorboard. placed. If both cables are being replaced, remove
tension device completely from both cables.
z Remove cover plate (2) and release hydraulic
pressure from system with manual lowering valve z Tape a couple of wires from control cable to a small
(23) located on end of solenoid valve SV1. electrical wire pull, a device used by electricians to
pull a wire from outlet to outlet through a wall, or a
z Remove hydraulic hose (19) from hydraulic unit similar device. Keep the taped area as small as
and put a shop rag or two below to catch any oil possible but make sure cable is secure.
that may run out. Plug hydraulic hose (19) with a #6
hydraulic plug, Crown part no. 064220-002. z Stand on operator platform and pull control cable
out the top of the platform mast.
z Remove electrical connections from hydraulic
pump motor M3, solenoid valve SV1, solenoid P1, z Now pull cable and wire pull out through bottom of
suppressor block SB21 and note wire locations. platform mast.
z Remove hydraulic unit from truck by removing nuts

(21) and lockwashers (24).
04 Rev. 7/04
86
Control Cables
z Remove old cable from wire pull and tape new ca- z Pull both cables tight and tighten strain relief.
ble to wire pull using the same method as three Tighten the strain relief nut until it bottoms out.
steps before. Make tape tight and bundle as small
as possible. z Loosen screw on tension device until cotter pin
(14) touches U shaped bracket.
z Carefully pull new cable back through and out top
of platform mast with wire pull. Apply rubber lube to z Install hydraulic unit back in vehicle and secure in
control cable if required. Make sure cable does not place. Make all electrical and hydraulic connec-
catch on lift cylinder, kink or tangle. tions to vehicle.
z Now use wire pull to pull cable through chassis z Connect batteries using remote located at front of
mast and into chassis area. Do not let cable kink or vehicle, raise mast and remove block. Raise and
tangle. lower mast one complete cycle. With mast com-
pletely lowered check oil level in hydraulic reser-
z Replace guides (22). Leave about 240 mm (9.5 in) voir, fill as required. Raise and lower mast thru at
of cable hanging out bottom of platform mast. least five more cycles and then raise mast com-
pletely.
z Pull cable through hole on right or left side of plat-
form mast, determined by which cable is being re- z At top front of the chassis mast there is a slotted
placed. Make sure cable is seated in guide. hole and a slot in the second stage mast. The
bleed screw on the lift cylinder is directly behind
z Secure cable with cable clamps (15). those slots. Using a screwdriver loosen the bleed
screw about one half turn. When hydraulic oil starts
z Plug cable plugs CA101 and CA102 into mating to seep out, tighten the bleed screw.
connector on right or left side of platform bottom.
z Lower the mast completely and check hydraulic oil
z Install strain relief parts, double shoulder washer level in reservoir, fittings and connections for leaks.
and spring back on cable and tension bracket (11). If none are found, turn the vehicle off and replace
Do not tighten strain relief. platform floorboard, make connections to DMSR
and DMSL switches and replace load deck.
z Install tension device back in position, replace
screw (4), flatwashers (5), spacer and cotter pin z Run operational check.
(14).
z Tighten screw on tension device until spacer and Warning! Risk of property damage!
legs of tension bracket (11) bottoms out on chassis
Make sure all safety devices are
(7).
in place before running opera-
tional check.
04 Rev. 7/04
87
Control Cables
(
'
MS-2450-040
88
Control Cables
1 Fixation 22 Guide
2 Cover Plate 23 Rubber Insert
3 Screw 24 Lockwasher
4 Flatwasher 25 Manual Lowering Valve
8 End Cap 26 Platform Mast
9 Tension Bracket 27 Third Stage Mast
10 Cotter Pin 28 Stud
11 Screw 29 Second Stage Mast
12 Cable Clamp 30 Chassis
13 Mounting Nut 31 Chassis Mast
14 Cable Track Mounting
15 Mounting Nut CA101 Connector
16 Cable Clamp CA102 Connector
19 Mast Cap M3 Hydraulic Pump Motor
20 Hydraulic Hose P1 Solenoid
21 Nut SV1 Solenoid Valve
Control Cable Re-tension z Disconnect connectors (CA101, CA102) and re-

move cable clamps (16, 12) on either side of plat-
Control cables are routed through the mast pulleys and form mast (26) and third stage mast (27).
are kept seated by a tension device located in front of
the chassis mast on the chassis. After adjustment, z Pull cables and plugs through holes in bottom right
each control cable will have approximately 11.3 kg and left hand sides of platform.
(25 lb) of pull. To obtain proper cable tension adjust as
follows: z Pull cables tight from bottom of third stage mast
(27) around the mast studs and secure with cable
z Adjusting chain and platform height after tension- clamp (12).
ing control cables can induce stress or loosen ca-
bles. Ensure chains and platform height are ad- z Pull remaining cable tight from bottom of platform
justed properly prior to tensioning cable. mast (26).
z Raise platform and block using a hardwood block. z Feed cables back up through platform mast (26).
z Turn key switch off and remove load deck from ve- z Replace cable clamps (16) and plug into mating
hicle. connectors (CA101, CA102).
z Disconnect batteries. z Loosen screw (3) until cotter pin (10) bottoms out
on tension bracket (9).
z Disconnect connector CA303 for DMSR and
DMSL switches located below rear part of floor- z Replace floorboard, cover on chassis, and connect
board chassis, remove floorboard, and cover on plug CA303 for DMSR and DMSL switches.
chassis.
z Connect batteries, replace load deck, unblock
z Tighten screw (3) until tension bracket (9) has bot- mast and lower.
tomed out against chassis.
89
Control Cables
Cable Replacement z Remove electrical connections from hydraulic
pump motor (M3), solenoid valve (SV1), solenoid
If a control cable needs to be replaced the following (P1), suppressor block SB21 and note wire loca-
procedure should be followed: tions.
z Ensure chains and platform height are adjusted z Remove hydraulic unit from truck by removing nuts
properly prior to tensioning cable. (21) and lockwashers (24).
z Using service panel, raise platform until cable track z Remove control cable connections from TB201,
mounting (14) on third stage mast (27) is visible. TB202 or both depending on which cable or cables
Temporarily block platform. Remove track mount- are going to be replaced. Note wire locations on
ing nuts (13) and push studs (28) out of holes. terminal blocks. If one cable is being replaced due
Lower track slightly so that studs (28) are both be- to wear, it would be best to replace both control
low mounting plate on mast. cables.
z Relieve all tension on control cables by taking cot-

Danger! Risk of trapping and severing ter pin (10), screw (3) and flatwashers (4) from ten-
limbs! sioning device.
ments can sever limbs or even z Disconnect connectors (CA101, CA102) and cable
cause fatal injuries. Always clamps (16) on platform and drop cable down
block mast when working on ve- through holes in platform. Remove cable track
hicle with mast in elevated posi- mounting nuts (15) from platform and push studs
tion. (28) through mounting holes.
z Remove blocks and lower platform until it is ap- z Remove guide (22) and shims at lower left or right
proximately 915 mm (36 in) from the ground side of platform mast (26), depending upon which
(measured to the top of the platform rear skirt). cable is being replaced. Remove cable clamp (12)
from third stage mast. Pull cable and track down
z Block platform, turn key off, remove load deck and from in between platform mast (26) and third stage
disconnect batteries. mast (27).
z Remove mast cap (19) from top of platform z Remove “J” shaped groove cable guides (22) from
mast (26). third stage mast (27).
z Disconnect connector CA303, for DMSR and z Pull both cables out of chassis mast (31) at ten-
DMSL switches located below rear part of floor- sioning device end about 240 mm (9.50 in) or until
board chassis, remove floorboard. connectors (CA101, CA102) are even with bottom
of platform mast (26). Do not put any strain on
z Remove cover plate (2) and release hydraulic plugs by trying to pull cables out too far.
pressure from system with manual lowering valve
(25) located on end of solenoid valve (SV1).
z Remove hydraulic hose (20) from hydraulic unit.

Place a shop rag or two below connection to catch
any oil that may run out. Plug hydraulic hose (20)
with #6 hydraulic plug (064220-002).
90
Control Cables
z Remove strain relief end cap and rubber insert (8) z Form cable track into a “U” shape and push up in
from cable that is being replaced. Do not loosen between third stage mast (27) and platform stage
strain relief at all on cable that is not being re- mast (26). Line up studs (28) with platform mount-
placed. If both cables are being replaced, remove ing holes and fasten nuts to studs (28).
tension device completely from both cables.
z Feed cable back up through holes in platform and
z Tape a couple of wires from control cable to a small reconnect connectors (CA101, CA102). Re-install
electrical wire pull, a device used by electricians to cable clamps (16) to platform. Replace guides (22)
pull a wire from outlet to outlet through a wall, or a at bottom of platform mast (26).
similar device. Keep the taped area as small as
possible, but make sure cable is secure. z Install strain relief parts, double shoulder washer
and spring (6) back on cable and tension
z Stand on operator platform and pull control cable bracket (9). Do not tighten strain relief.
out the top of the third stage mast (27).
z Install tension device back in position and replace
z Now pull cable and wire pull out through bottom of screw (3), flatwashers (4), spacer and cotter
third stage mast (27). pin (10).
z Remove old cable from wire pull and tape new ca- z Tighten screw (3) on tension device until spacer
ble to wire pull using the same method as three and legs of tension bracket (9) bottoms out on
steps before. Make tape tight and bundle as small chassis (30).
as possible.
z Pull both cables tight and tighten strain relief.
z Carefully pull new cable back through and out top Tighten the strain relief nut until it bottoms out.
of third stage (27) mast with wire pull. Apply rubber
lube to control cable if required. Make sure cable z Loosen screw on tension device until cotter pin
does not catch on lift cylinder, kink or tangle. (10) touches “U” shaped tension bracket (9).
z Now use wire pull to pull cable through chassis z Install hydraulic unit back in vehicle and secure in
mast (31) and into chassis (30) area. Do not let ca- place. Make all electrical and hydraulic connec-
ble kink or tangle. tions to vehicle.
z Pull cables straight down in between second stage z Connect batteries, using remote located at front of
mast (29) and third stage mast (27). Re-attach “J” vehicle, raise mast until cable track mounting to
shaped groove cable guides (22). Pull cable out third stage mast (27) is visible and re-block plat-
the side and around studs (28). Pull cable up and form mast (26). Reconnect cable track to mounting
attach cable clamp (12) to side of third stage plate on third stage mast (27).
mast (27), maintaining tension until clamp (12) is
tight.
91
Control Cables
z Raise mast and remove blocks. Raise and lower z Lower the mast completely and check hydraulic oil
mast one complete cycle. level in reservoir, fittings and connections for leaks.
If none are found, turn vehicle off and replace plat-
z With mast completely lowered check oil level in hy- form floorboard, make connections to DMSR and
draulic reservoir, fill as required. DMSL switches and replace load deck.
z Raise and lower mast through at least five more z Run operational checks.
cycles, then raise mast completely.
z At top front of chassis mast (31) there is a slotted Warning! Risk of property damage!
hole and a slot in second stage mast (29). The
bleed screw on the cylinder is directly behind those
slots. Using a screwdriver, loosen the bleed screw
tional check.
about one half turn. When hydraulic oil starts to
seep out, tighten the bleed screw.
92
Keypad
Keypad A 4-digit Personal Identification Number (PIN), can be

assigned for each operator that uses the vehicle. There
are hierarchy levels of security built into the keypad (1).
The WAV50 Series can be equipped with an electronic We refer to these levels as Dealer, Manager, Supervi-
keypad (1) in place of the keyswitch. The keypad (1) sor, Operator and Service. Each set of instructions is
offers an enhanced level of security to deter unauthor- formatted towards a particular party by both title and
ized or untrained personnel from operating the vehicle. color. For example the blue programming instructions
contain all levels of security information for the dealer.
The green instructions are geared for customer man-
agement and the yellow for customer appointed super-
visors. Operator and Service access is explained on
the appropriate programming instruction sheets. These
sheets are sent with each new WAVE vehicle equipped
with a keypad (1) and with field installable option,
127764.
MS-2450-029
1 Keypad
2 Steering Control Pod
01 Rev. 3/01
93
Keypad
Keypad Programming Features z During programming the yellow LED (1) indicates
the unit is in program mode, green LED (1) indi-
(Refer to appropriate programming instructions) cates a key has been depressed.
z A steady green LED (1) means a successful PIN

has been entered and vehicle can be operated.
z If 3 successive invalid PIN(s) are entered, both

LED’s (1) will flash and an alarm will sound for 1
minute. After LED’s (1) stop flashing and alarm is
silent, then a valid PIN can be entered.
z At vehicle turn "ON", if the keypad senses an over-

load, the unit will shut down and emit a dual-tone
"beep" plus both LED's (1) will flash four times.
z Key pad comes with 10 pre-programmed operator

level PIN's. These codes can be used, deleted or
new ones created by the supervisor.
z Up to 200 PIN's can be entered and stored.
z Supervisor can "lockout" vehicle through keypad.
z Supervisor can program keypad to turn vehicle

"OFF" automatically if vehicle is idle for prolonged
periods.
z Dealer maintains service PIN to operate vehicle for

MS-2450-041 PM's and repair maintenance. This PIN Can Not be
erased by customer. Factory Preset.
1 LED
2 Enter Key
01 Rev. 3/01
94
Keypad
Keypad Specifications Keypad Replacing Key Switch
z Power input is 15 A external fused, 48 V maxi-

mum. Keypad Replacing Key Switch
z Power output is 10 A maximum. Red Wire Key Pad

Module
z Operating temperature operating range is -40 to White Wire
+ 85°C. Remove W/Red Stripe
Key Switch
Green Wire
z Keypad contains an EE prom for memory retention KYS
Battery Negative
of programmed PIN codes. Fuse
To Vehicle
*"Idle" sense lines for operation of "Auto Power Off +BV (24V)
Control Wiring
Timeout". One or the other is used, not both. Black wire
is for sensing "positive" switched line (foot switch etc.).
White wire is for "negative" switched line (Logic Input).
Insulate unused wire. 8591
Keypad Block Diagram Part of Platform Wiring Diagram
Keypad Block Diagram

Steering Control Pod
CA701
White Wire Power YEL 19 STR POT POS 9.75V=ON
W/Red Stripe Switch Static POT1 GRN 21 STR POT NEG 2.52V=ON
(STRG) 8.75V=Full Left
Left RED 20 STR POT Wiper 6.25V=Neutral
Driver CA501 2902 To CA706 3.67V=Full Right
3 Key SW IN 0V=Open, 24V=Closed
Alarm LED’S (2) 2910 1 2901 To CA705
2911 2 2903 To CA706 1
Battery Positive 003 3 001 5 Can HI 0V=Off, 2.9V=ON

Red Wire Voltage 004 4 002 6 Can LO 0V=Off, 2.9V=ON
Regulator Microprocessor 504 5 501 532 4 Batt NEG 0Volts
Green Wire
5905 6 5901 15 HTS20 IN 20V=Open, V=Closed
Battery Negative
5906 7 5902 14 High SPD IN 20V=Open
8.75V=Full Forward
*White Wire Filter & Key Pad
102 8 101 Traction POT Wiper 5.86V=Neutral
3.67V=Full Reverse
602 9 601
*Black Wire Interface 702 10 701
Traction POT NEG 2.52V=ON
22 Traction POT POS 9.75V=ON
2987 11 2986 12 PORS IN 9.75V=ON, 24V=Open
*"Idle" sense lines for operation of "Auto Power Off Timeout". 902 12 CA703
One or the other is used, not both. Black wire is for sensing 532 1 GRN
"positive" switched line (foot switch etc.). White wire is for CA704 BDI
"negative" switched line (Logic Input). Insulate unused wire. 2962 1 BLK
KEYPAD
CA705
Presence
From Pin 1 CA501 2901 1 RED
Display
From Pin 3 CA701 2902 CA706
1 R/W
8590 From Pin 2 CA501 2903
UNUSED WHT Fault
RCV IN
RCV OUT
LED IN
LED OUT
WHT 10 RCV IN
BLU 11 RCV OUT
LHS
GRN 9 LED IN
ORG 8 LED OUT 13 7 17 18
Part Of Platform
ORG
WHT
GRN
BLU
Wiring Diagram
To Traction Pod
8580
01 Rev. 3/01
95
Keypad
Wiring Color Codes Number
The following information is an explanation of wiring Each wire is assigned a three or four digit number. The
color codes used. first one or two digits will identify the color of the wire
and the last two digits are the sequential numbering of
the wires from 01 to 99.
Color
Wire colors will be limited to those in the chart. The

color of the wire will be chosen based on the function
of the circuit in which it is used.
Abbreviation Color Number Circuit function
BLK Black 0** a Digital Signal
BRN Brown 1** Analog Signal

RED Red 2** Battery Positive
ORG Orange 3** +12 volts (DC - DC converter)
YEL Yellow 4** Third DC - DC converter
GRN Green 5** Battery Negative
BLU Blue 6** Isolated Negative
VIO Violet 7** +5 volts (DC - DC converter)
GRAY Gray 8** Fourth DC - DC converter
WHT White 9** Miscellaneous
R/W Red Stripe on White 29** Battery Positive after a switch
G/W Green Stripe on White 59** Battery Negative after a switch or resistor
a. Sequential number from 01 to 99
01 Rev. 3/01
96
Keypad
Symbol Description Symbol Description
Momentary Contact Switches

Mechanically Operator Actuated
Normally open Held Open
Held Closed Normally Closed
Momentary Contact Switches

Mechanically Actuated
Normally Closed
Normally open
Held Open
Normally open
Normally Closed
Held Closed
Basic symbols
Fuse Battery
Inductor Non-polarized capacitor
Potentiometer Mov or Transzorb
Power Termination Connection Point
Mast Cable Horn
Diode Solenoid Valve or Relay

With Suppression
01 Rev. 3/01
97
Keypad
Symbol Description Symbol Description
Normally Closed Normally Open
Plug PC Connector CA
Jack JC PM Motor
Wound Motor Armature Motor Field
Lamp Suppressor
s
Remote Negative
01 Rev. 3/01
98
System controller, CURTIS 1703
System controller, CURTIS 1703 Maintenance
The System Controller is a solid state electronic control There are no user-servicable parts inside the Curtis
for vehicle operation. All vehicle functions are control- PMC 1703 controller. No attempt should be made to
led by this unit except for brake release when the Push/ open the controller. Opening the controller may dam-
Drive switch is in the Push position. age it and will void the warranty. However, it is recom-
mended that the controller exterior be cleaned periodi-
z As a vehicle control, the 1703 Controller processes cally, and if a handset is available this periodic cleaning
inputs from operator controls and vehicle monitor- provides a good opportunity to check the controller’s
ing devices to provide the desired vehicle action. diagnostic history file.
z During power up of the vehicle, a system self-test

is performed by the controller to make sure system Safety
integrity is present for operation.
The 1703 controller is inherently a high power device.
z As a speed control, the 1703 enables the energy When working around any battery powered vehicle,
from the batteries to be fed to the electric motors proper safety precautions should be taken. These in-
smoothly through the use of power transistors. clude, but are not limited to: proper training, wearing
eye protection, avoiding loose clothing and jewelry,
z Specific functions of the speed control are adjusta- and using insulated wrenches.
ble by using a plug-in handset. These are covered
in the Electrical System Settings section of this
manual.
Cleaning
z The speed control portion of the control is also the Although the 1703 controller requires virtually no main-
steering control of the vehicle. By powering the tenance if properly installed, the following minor main-
drive motors at different levels, the vehicle will tenance is recommended in certain applications:
steer in the direction requested by the operator in-
put. z Remove power by disconnecting the battery.
z The controller also contains the ability of perform- z Discharge the capacitors in the controller by con-
ing diagnostics on the vehicle. Through the status necting a load (such as a contactor coil or a horn)
code interface (display or handset), status codes across the controller’s B+ and B- terminals.
will be displayed and by using the status code de-
scriptions in this manual, the maintenance techni- z Remove dirt or corrosion from the bus bar area.
cian will be directed to the problem area for repair. The controller should be wiped clean with a moist
More information on this feature is located in the rag. Allow it to dry before reconnecting the battery.
Electrical – Troubleshooting section of this manual.
z Make sure the connections to the bus bars are
tight. Use two well insulated wrenches for this task
in order to avoid stressing the bus bars.
01 Rev. 10/04
99
Special Tools
Mini Fit Connector
The connector required to connect the control to the

vehicle circuitry requires 117615 extraction tool (see
illustration 2621) and 117636 crimping tool (see
illustration 2644P). Most other connectors require
118993 extraction tool (see illustration 6848P). These
tools are available from Crown. See reference page 30 6848P
in parts manual.
118993 Extraction Tool
Curtis Handset
The handset is used to input calibration settings, mon-

itor inputs and outputs, and as a diagnostic aid for trou-
bleshooting.
2621
117615 Extraction Tool
2644P MS-2450-042
117636 Crimping Tool 130475 Curtis Handset

130480 Replacement Cord
100
Handset Operation The handset displays the controller’s model number,

1-1
date of manufacture,and software revision code when

first plugged in. Following this initial display, the hand-
The optional universal Curtis handset allows you to set displays the Main Menu, which is the starting point
program, test, and diagnose Curtis PMC 1703 control- for all basic programmer functions. If there are no en-
lers. The handset is powered by the host 1703 control- tries within a Menu, then that Menu title will not be dis-
ler, via a molex connector located in the end of the con- played.
troller.
10468
MS-2450-043
1 Display Screen
LCD screen capable of displaying up to 7 lines of text and
graphics simultaneously.
2 DATA INC/DEC key
Changes value of the parameter indicated by the cursor.
3 Bookmark Keys
Allow you to quickly go back to your favorite selections wit-
hout having to navigate back through the Menu.
4 Menu Navigation Key
Moves screen cursor up or down through Menu list (top and
bottom arrows), and opens or closes Sub Menus (right and
left arrows).
101
The blinking square indicates the location of the cursor. From this Sub-Menu you can go to another Sub-Menu
When at the top-level Menu only one column of cursor using the right arrow on the Menu Navigation Key to a
positions exist. Additional columns will be shown using screen with additional information and bar graph.
the 4-directional Menu Navigation Key to go deeper
into the Menu structure. Using the right arrow on the
Menu Navigation Key to enter a Main Menu Title brings
Program
up a Sub-Menu indented to the right and displayed in a
second column. Max Speed
92%
Program Min Max
Max Speed 92% 10 100
Acceleration 1.2s
Monitor 10533
Faults
Functions To change the value of the parameter use the Data Inc/
Information Dec Key. Use the left arrow on the Menu Navigation
Key to back out of the Sub-Menus to the Main Menu.
10532
To bookmark a position in the Menu, hold down a
Bookmark Key for 3 seconds, until the Bookmark set
screen is displayed. After bookmark is set use the ap-
propriate Bookmark Key to jump to the wanted book-
mark position. The bookmarks are not permanently
stored and are cleared when the programmer is un-
plugged.
102
Handset Menus Program Menu
The Main Menu is the starting point for all Curtis pro- The Program Menu may contain several Sub-Menus of
grammable products. All basic functions are readily ac- parameters. The unit is setup with specific operating
cessed from this point. conditions using the Curtis handheld programmer in
this Menu
Information
Entries marked with (*) are only
accessable with OEM handset.
DO NOT adjust without first ob-
taining factory authorization.
Failure to do so will result in
Warranty being voided.
.
Menu/Sub-Menu Description
* SECONDARY C/L a Secondary Current Limit in amps
* MAIN C/L Main Current Limit in amps

* C/L TIME Current Limit Time in seconds
ACCEL RATE Acceleration Rate in seconds
DECEL RATE Deceleration Rate in seconds
* THRTL DEADBAND Throttle Deadband in %
LOW SPEED Low Speed in %
LOW SPEED (2) Low Speed (2) in %
LOW SPEED (3) Low Speed (3) in %
REVERSE SPEED Reverse Maximum Speed in %
ANTI-ROLLBACK Anti-Rollback in volts
* H/S TURN RATE High Speed Turn Rate in %
* L/S TURN RATE Low Speed Turn Rate in %
* ACC TURN RATE Acceleration Turn Rate in seconds
* TURN RECOVERY Turn Recovery in seconds
BRAKE DLY Brake Delay in seconds
SLEEP DLY Sleep Delay in minutes
* CURRENT CALIB Current Calibration in m-ohms
M1 MAX SPEED Rail Guidance Maximum Speed in %
M2 MAX SPEED Rail Guidance Speed Limit in %
MAX SPEED Forward Maximum Speed in %
BALANCE Balance
* OPPOSITE STEER Reverse Steering
01 Rev. 10/04
103
PERF SELECT Performance Select

BATTERY RATE Battery Rate
GUIDANCE Rail Guidance Enable/Disable
TILT Tilt Sensor Enable/Disable
SRO ALARM Static Return to Off Alarm Enable/Disable
* PRESENCE Presence Sensors Enable/Disable
REVERSE ALARM Reverse Alarm Enable/Disable
FORWARD ALARM Forward Alarm Enable/Disable
LIFT ALARM Lift Alarm Enable/Disable
LOWER ALARM Lower Alarm Enable/Disable
DRIVE CODE Driver Code Enable/Disable
VALUE 1 First Digit Code Selection
VALUE 2 Second Digit Code Selection
VALUE 3 Third Digit Code Selection
VALUE 4 Fourth Digit Code Selection
VALUE 5 Fifth Digit Code Selection
FACTORY VALUES Revert To Standard Settings
CALIBRATION 1 Drive Potentiometer Forward Calibration
CALIBRATION 2 Drive Potentiometer Neutral Calibration
CALIBRATION 3 Drive Potentiometer Reverse Calibration
CALIBRATION 4 Steering Potentiometer Left Calibration
CALIBRATION 5 Steering Potentiometer Neutral Calibration
CALIBRATION 6 Steering Potentiometer Right Calibration
* CALIBRATION 7 Drive Hour Meter Reset
* CALIBRATION 8 Lift Hour Meter Reset
* F/R THROTTLE % Drive Forward/Reverse Throttle Request Percentage
R/L THROTTLE % Steering Right/Left Throttle Request Percentage
RT MOTOR CUR Right Motor Current
LT MOTOR CUR Left Motor Current
RT MOTOR VOLT Right Motor Voltage
LT MOTOR VOLT Left Motor Voltage
BATT VOLTAGE Battery Voltage in 1/10 Volt
HEATSINK (degrees)C Heatsink Present Temperature
MAX TEMP (degrees)C Heatsink High Temperature Since Power Up
01 Rev. 10/04
104
MIN TEMP (degrees)C Heatsink Low Temperature Since Power Up

HIGH SPEED IN High Speed Input, on=closed, off=open
EM BRAKE DRVR Emergency Brake Driver, on/off
INHIBIT IN Controller Inhibit Input Signal, on=closed, off=open
FOOT INPUT Foot Brake Switch Inputs, on=closed, off=open
MAIN CONT Emergency Disconnect Contactor Driver, on/off
PUMP CONTACTOR Pump Contactor Driver, on/off
LOWER CONT Lower Solenoid Driver, on/off
SPARE CONT Spare Contactor Driver, on/off
LEFT SPEED Left Motor Speed Percentage
RIGHT SPEED Right Motor Speed Percentage
SPEED Percent of Maximum Speed
BATTERY LEVEL Battery Charge Remaining Percentage
DRIVE HRS Drive Hours
DRIVE HRS X100 Drive Hours times 100
PUMP HRS Pump Hours
PUMP HRS X10 Pump Hours times 10
HEIGHT INPUT Height Input, on=closed, off=open
LEFT HAND Left Hand, on=presence, off=no presence
RIGHT HAND Right Hand, on=presence, off=no presence
GATE OPEN Gate Open, off=closed, on=open
GATE CLOSED Gate Closed, on=closed, off=open
GUIDANCE INPUT Guidance Input, on=closed, off=open
TILT INPUT Tilt Input, on=closed, off=open
PRESENCE ORS Presence Over Ride Switch, on=closed, off=open
HEIGHT INPUT 2 Height Input, on=closed, off=open
EC SWITCH Elevation Control Switch, on=closed, off=open
MOTOR COVER Motor Cover Input, on=closed, off=open
INPUT HIGH 3 Input High 3, on=closed, off=open, spare H3
INPUT LOW 3 Input Low 3, on=closed, off=open, spare L3
STEER INPUT Steering Direction Input, -1=left, 1=right
DRIVE INPUT Drive Direction Input, -1=reverse, 1=forward
01 Rev. 10/04
105
Speed Mode
0=normal
SPEED MODE 1=Speed Limit 1
2=Speed Limit 2
3=Rail Guidance Speed Limit
4=Rail Guidance Maximum Speed
5=Presence Over Ride/Speed Limit 3
6=Rail Guidance Speed Limit 3
RAIL MODE Rail Mode, on=in rail, off=open aisle
PUMP INHIBIT Pump Inhibit, on/off
a. Entries marked with (*) are only accessable with OEM handset. DO NOT adjust without first obtaining
factory authorization. Failure to do so will result in Warranty being voided.
01 Rev. 10/04
106
Faults Menu – HARDWARE FAILSAFE 2
– INHIBIT
The Faults Menu provides the present status and ac-
cess to past fault history. – LEFT POWER FAULT
z SYSTEM FAULTS – LOW BATTERY VOLTAGE
– MAIN CONT DRVR OC

z FAULT HISTORY
– MAIN CONT FAULT
z CLEAR FAULT HISTORY
– MOTOR COVER WARNING
This is not a menu as such, but simply a list of the pos- – MOTOR SHORT
sible messages you may see displayed when the pro-
grammer is operating in Faults Menu. The messages – MOTOR STALL
are listed in alphabetical order for easy reference.
– NO KNOWN FAULTS
– BRAKE DRIVER OC
– OVERVOLTAGE
– BRAKE FAULT
– PRESENCE SENSOR
– CAN
– RIGHT POWER FAULT
– C/L
– SFW
– CODE INPUT
– SRO FAULT
– CONFIG LOST
– STEER THROTTLE
– CUR MEASURE
– THERMAL HIGH
– DRIVE THROTTLE
– THERMAL LOW
– FRAM FAULT
– THERMAL WARNING
For further information on diagnostic messages, refer

to the service codes in section "controller troubleshoot-
ing“ page 119.
107
Functions Menu Programmer Setup Menu
The Curtis handheld programmer can also be used to There are several setup options and information that
copy data between units, reset data and many other can be accessed in this Menu.
functions unique to the unit.
z PROGRAM
z SETTINGS
– LCD CONTRAST
– GET SETTINGS FROM CONTROLLER – LANGUAGE
– WRITE SETTINGS TO CONTROLLER
z INFORMATION
– RESET ALL SETTINGS
– OEM INFO
Information Menu – RECONFIGURED
– MODEL NUMBER
When the Curtis handheld programmer is connected to – SERIAL NUMBER
the unit information, such as software, hardware and
– MANUFACTURING DATE
parameter block versions are also uploaded.
– SOFTWARE VERSION
z MODEL NUMBER – HARDWARE VERSION
– MC PROTOCOL VER
z SERIAL NUMBER
– ES PROTOCOL VER
z MFG DATE – S PROTOCOL VER
– DEVICE TYPE
z SOFTWARE VERSION
108
Controller Settings
Controller Settings
The Curtis 1703 system controller is set up by the use
of a handset which plugs into a socket in the end of the
controller.
Following are the explanation of:
z Programmable features and calibration.
z Controller cloning.
z Feature descriptions.
z Chart of settings which provide acceptable per-

formance.
MS-2450-043
1 Display Screen
2 DATA INC/DEC Key
MS-2450-044 Changes value of the parameter indicated by the cursor.
3 Bookmark Keys
1 Bus Bar Connections for Power Circuitry Allow you to quickly go back to your favorite selections wit-
2 Service Terminal Connects to CA402 hout having to navigate back through the Menu.
3 Control Wiring Connects to CA401 4 Menu Navigation Key

left arrows).
01 Rev. 10/04
109
Controller Settings
Features and Calibration Cloning Controllers
z Control must be calibrated to the steering and drive The handset can be used to "clone" controls. That is
potentiometers. When these items are replaced, taking the settings of one control and transferring these
perform the Calibration 1 to 6 steps as necessary, settings to any number of additional controls thus mak-
page 116. ing a family of controls with identical settings. Even
though this also can be done by individually setting
z Drive and lift hour meters can be reset when in this each parameter, "cloning" can save considerable time
mode of handset operation. Refer to the Calibra- in multiple vehicle sites.
tion 7 and 8 features for instructions, page 117.
z Cloning ability of the handset is in the Functions
z Driver Code feature of the vehicle is set in this Menu. Scroll to the Functions Menu, using the right
mode of operation. Refer to Feature Description of arrow of the Menu Navigation Key enter the Set-
Values 1 to 5 for instructions, page 115. tings Menu.
z Features that change vehicle performance are ad- z From the Settings Menu select the Get Settings
justable in this mode of operation. From Controller to upload the data from a unit into
the handset.
Handheld Programmer z Select the Write Settings To Controller to down-

load the present data stored in the handset to the
z Plug the handset into the connector on the end of unit.
the controller.
z To restore the original settings of the unit select the
z From the Main Menu, Use the up and down arrows Reset All Settings menu.
on the Menu Navigation Key to locate the cursor on
the Program menu. z Each time the programmer is connected to a unit,
it uploads the present data and stores it in a "tem-
z Press the right arrow on the Menu Navigation Key porary archive" memory so you can revert back to
to enter the Sub-Menus. the original settings at any time during a program-
ming session.
z Scroll through the Sub-Menus using the up and
down arrows on the Menu Navigation Key until de-
sired parameter for adjusment is located.
z Press the right arrow on the Menu Navigation Key

to enter the parameter adjustment screen, using
the Data Inc/Dec Key, Adjust the value of the se-
lected parameter to match the setting in chart 1 or
to a different setting to change performance of the
vehicle.
z When all settings are complete, disconnect the

handset and return vehicle to service.
110
Controller Settings
Feature Description * C/L Time

C/LTime/secs
The titles for each adjustment may have three lines. Current Limit Time
• Maximum amount of time controller permitted to
z First line of the description is the message as seen
be at Main Current Limit before current limit
on the handset in the PROGRAM mode.
rolled back to Factory C/L level.
z Second line is the message as seen in the MORE • Adjustment range is 0 to 5 s.
INFO mode. • Decreasing number reduces time controller will
allow Main C/L level.
z Third line is an extended description when neces-
sary. Accel Rate
Acceleration Rate, secs
Information • Amount of time required to accelerate from a
minimum speed to maximum forward speed.
Entries marked with (*) are only
• Adjustment range is 2.3 to 5.2 s.
accessable with OEM handset.
• Decreasing the number displayed on the hand-
set will increase the force of acceleration.
Failure to do so will result in Decel Rate
Warranty being voided. Deceleration Rate, secs
• Amount of time required to decelerate from max-
* Secondary C/L imum speed to minimum forward speed.
Factory C/L, amps • Adjustment range is 1.0 to 2.3 s.
Factory Current Limit • Decreasing the number displayed on the hand-
• After the controller senses the current draw ex- set will increase the force of deceleration.
ceeding the Main Current Limit for the C/L Time, * THRTL Deadband
current will be limited to this setting. This setting Throttle Deadband
cannot be greater than Main C/L. • Adjusts the amount of rotation of potentiometers
• Adjustment range is 0 to 100 A. before out of neutral condition is realized by the
• Increasing the number value increases the cur- controller (neutral window). Parking brake re-
rent draw permitted. leases when out of window condition is realized.
* Main C/L • Adjustment range is 10 % to 50 %.
Main Limit, Amps • Increasing number value increases amount of
potentiometer rotation required before out of
Main Current Limit
neutral condition is realized.
• Maximum current draw permitted by the control-
ler.
• Adjustment range is 0 to 100 A.
• Increasing number increases current draw per-
mitted.
111
Controller Settings
Low Speed Anti-Rollback
Low Speed, % Anti-Rollback
• Maximum allowable forward speed when the • Sets the minimum voltage motors are supplied
platform lift height is below 510 mm (20 in) and when traction command is given.
the platform gates are not fully open. • Adjustment range is 0 to 1.0 V.
• Adjustment range is 35 % to 52 %. The maxi- • Increasing number value increases voltage.
mum speed of Speed Limit 1 is 75 % of Forward * H/S Turn Rate
Maximum Speed.
High Speed Turn Rate
• Decreasing the percentage, decreases the
• Sets turn radius with truck travelling at maximum
speed.
speed.
Low Speed (2) • Adjustment range is 18.6 % to 37.4 %.
Low Speed (2), % • Higher the number setting the smaller the turn
• Maximum allowable forward speed when the radius.
platform lift height is above 510 mm (20 in) and * L/S Turn Rate
the platform gates are fully closed.
Low Speed Turn Rate
• Adjustment range is 0 to 35 %. The maximum
• Sets the speed of a turn with no traction com-
speed of Speed Limit 2 is 50 % of Forward Max-
mand.
imum Speed.
• Adjustment range is 8.4 % to 19.6 %.
• Higher the number the faster the turn.
speed.
* Acc Turn Rate
Low Speed (3)
Accel Turn Rate, secs
Low Speed (3), %
• Rate (time) required to reach the requested turn
• Maximum allowable forward speed when the
speed.
platform lift height is above 2135 mm (84 in) and
• Adjustment range is 0.5 to 5.2 s.
the platform gates are fully closed.
• Higher the number the lower the rate of reaching
• Adjustment range is 0 to 17 %.
the requested turn speed. Setting too high will
increase weaving and setting too low will in-
speed.
crease jerking.
Reverse Speed
Reverse Speed, %
Reverse Maximum Speed
• Maximum allowable reverse speed.
• Adjustment range is 0 to 35 %. The maximum
reverse speed is 50 % of the Maximum Forward
Speed.
• Decreasing number displayed decreases the
maximum allowable speed.
01 Rev. 10/04
112
Controller Settings
* Turn Recovery M1 Max Speed
Turn Recovery, s Mode 1 Maximum Speed, %
• Rate (time) required to reach 0 turn speed Rail Guidance Maximum Speed
(straight travel) after completing a turn. • Maximum allowable forward speed when in the
• Adjustment range is 0.5 to 5.2 s. rail guided mode of operation, platform lift height
• Higher the number the lower the rate of reaching is below 510 mm (20 in) and platform gates are
straight travel. Setting too high will increase fully open.
weaving and setting too low will increase jerking. • Adjustment range is 52 % to 100 %.
Brake DLY • Increasing number displayed on handset in-
Brake Delay, s creases vehicle speed.
• Sets time between the calculated stop of the ve- M2 Max Speed
hicle and the parking brake set. Mode 2 Maximum Speed, %
• Adjustment range is 0 to 0.5 s.
Rail Guidance Speed Limit
• Increasing number value increases delay time.
• Maximum allowable speed when vehicle is in rail
Number too low may cause parking brake to set
guided mode of operation, platform lift height is
too soon causing vehicle to jerk.
above 510 mm (20 in) and platform gates are
Sleep DLY fully closed.
Sleep Delay, min • Adjustment range is 0 to 69 %.
• Controller will shut down and require the key • Increasing the number on the handset increases
switch be cycled to "off" then "on" if set time the maximum allowable speed when in this
elapses without operator Foot Pedal input. mode of operation.
• Adjustment range is 0 to 60 min. Max Speed
• Increasing number displayed increases time be-
Maximum Speed, %
fore controller shut down.
Forward Maximum Speed
• "0" shuts Feature off.
• Maximum allowable forward speed.
* Current Calib
• Adjustment range is 0 to 69 %
• Current Calibration Constant
• Decreasing number displayed decreases the
• Defines how much current will flow through drive
maximum allowable speed.
motors.
• Adjustment range is 10 to 500 MΩ.
• Increasing number increases severity of vehicle
response to traction, steering and braking com-
mands.
113
Controller Settings
Balance Guidance
Balance Guidance Enable
• Adjustment to electrically make motors see the • Sets controller to accept rail guidance input sig-
same to provide straight travel with no steering nals.
input. • Selectable feature, on/off.
• Adjustment range is -85 % to +115 %. • Selecting on enables rail guidance feature.
• Vehicle drifts to the right with no steering input, Tilt
lower the number value. Vehicle drifts to the left
Tilt Enable
with no steering input, increase number value.
• When enabled and tilt sensor present, lift is dis-
* Opposite Steer abled when truck is on an incline above 510 mm
Opposite Steer Enable (20 in) with gates closed.
• Reverses turn direction of input for reverse • Selectable feature, on/off.
travel steering. • Selecting on enables feature.
• Selectable feature, on/off. SRO Alarm
• Selecting on causes reverse steering.
SRO Alarm Enable
Perf Select • When enabled, alarm is sounded whenever op-
Perf Select (1/2/3) erator attempts to operate vehicle using an im-
• Selects different performance levels for vehicle proper sequence of controls.
operation when switching to the turtle mode. • Selectable feature, on/off.
Level 1 is highest performance, level 2 is de- • Selecting on enables alarm feature.
creased performance and level 3 is lowest per- * Presence
formance.
Presence Enable
• Selectable feature: 1, 2 or 3.
• Requires the hands to be on grips during truck
Battery Rate operation.
Battery Rate • Selectable feature, on/off.
• Adjusts battery charge level obtained before lift • Feature enabled when on selected.
cutout. Reverse Alarm
• Adjustment range is 1 to 15.
Reverse Alarm Enable
• Selecting a higher number increases the rate of
• Alarm sounds whenever reverse direction of
battery discharge.
travel or spin is selected.
• Selectable feature, on/off.
• Operational when on is selected.
114
Controller Settings
Forward Alarm Value 1 thru 5
Forward Alarm Enable Value 1 thru 5
• Alarm sounds whenever forward direction of Driver Code Setting
travel or spin is selected. • Sets code the driver must input to make vehicle
• Selectable feature, on/off. operational.
• Operational when on is selected. • Code sequence is from 0 to 3. Setting a "0" re-
Lift Alarm quires the movement of the twist grip as if select-
Lift Alarm Enable ing forward direction of travel. Setting a "1" re-
• Alarm sounds whenever lift function is selected. quires movement of the twist grip as if selecting
• Selectable feature, on/off. the reverse direction of travel. Setting a "2" re-
• Operational when on is selected. quires moving rocker mechanism as if request-
ing a left hand turn. Setting a "3" requires moving
Lower Alarm
the rocker mechanism as if requesting a right
Lower Alarm Enable
hand turn.
• Alarm sounds whenever lower function is se- • "0" = forward
lected. "1" = reverse
"2" = left
• Operational when on is selected. "3" = right
Drive Code • Set code for operator actions desired.
Drive Code Enable Factory Values
• Unauthorized use of vehicle prohibited when en- Factory Values
abled. Will power up to a level which requires in-
Reset to Factory Values
put of predetermined code before power up is
• Resets adjustable features to settings from fac-
completed and vehicle is operational. Code set
tory.
with the Value 1 to 5 feature.
• These settings should match those listed
page 118.
• Feature enabled when on is selected.
• Reset feature, on/off.
• Selecting on resets all features to factory deter-
mined levels.
115
Controller Settings
Calibration 1 Calibration 4
Drive Potentiometer Forward Steering Potentiometer Left
• Permits calibrating a replacement drive potenti- • Permits calibrating a replacement steering po-
ometer tentiometer left direction movement to the con-
• forward direction movement to the controller. troller. Vehicle will not operate when using this
Vehicle will not operate when using this feature. feature.
• Selectable feature, on/off. • Selectable feature, on/off.
• Turn twist grip to full forward request direction • Press rocker mechanism for maximum turn to
and hold. left and hold. Press up arrow key to allow con-
• Press up arrow key to allow controller to accept troller to accept potentiometer value.
potentiometer value. Calibration 5
Calibration 2 Steering Potentiometer Neutral
Drive Potentiometer Neutral • Permits calibrating a replacement steering po-
• Permits calibrating a replacement drive potenti- tentiometer neutral position to the controller. Ve-
ometer neutral position to the controller. Vehicle hicle will not operate when using this feature.
will not operate when using this feature. • Selectable feature, on/off.
• Selectable feature, on/off. • Make sure rocker mechanism is in neutral posi-
• Make sure twist grip is in neutral position. Press tion.
up arrow key to allow controller to accept poten- • Press up arrow key to allow controller to accept
tiometer value. potentiometer value.
Drive Potentiometer Reverse Steering Potentiometer Right
• Permits calibrating a replacement drive potenti- • Permits calibrating a replacement steering po-
ometer reverse direction movement to the con- tentiometer right direction movement to the con-
troller. Vehicle will not operate when using this troller. Vehicle will not operate when using this
feature. feature.
• Turn twist grip to full reverse request direction • Press rocker mechanism for maximum turn to
and hold. right and hold. Press up arrow key to allow con-
• Press up arrow key to allow controller to accept troller to accept potentiometer value.
potentiometer value.
116
Controller Settings
* Calibration 7 * Calibration 8
Drive Hour Meter Reset Lift Hour Meter Reset
• Resets the drive hour meter to "0" hours. • Resets the lift function hour meter to "0" hours.
• Selecting on resets the hours accumulated on • Selecting on resets the hours accumulated on
the drive hour meter to "0". the lift function hour meter to "0".
117
Controller Settings
Handset Function Factory Setting

Information
Entries marked with (*) are only Max Speed 69 %
accessable with OEM handset. Balance 100 %
* Opposite Steer off
Failure to do so will result in Perf Select 1
Warranty being voided. Battery Rate 7
Guidance off
Tilt off
Handset Function Factory Setting
SRO Alarm on
* Secondary C/L 60 A * Presence on
* Main C/L 89 A Reverse Alarm off
* C/L Time 5s Forward Alarm off
Accel Rate 2.3 s Lift Alarm off
Decel Rate 1.8 s Lower Alarm off
* THRTL Deadband 17 % Drive Code off
Low Speed 43 % Value 1 see description, page 115
Low Speed (2) 35 % Value 2 see description, page 115
Low Speed (3) 12 % Value 3 see description, page 115
Reverse Speed 35 % Value 4 see description, page 115
Anti-Rollback 0V Value 5 see description, page 115
* H/S Turn Rate 33.2 % Factory Values see description, page 115
* L/S Turn Rate 14 % Calibration 1 see description, page 116
* Acc Turn Rate 0.8 s Calibration 2 see description, page 116
* Turn Recovery 0.5 s Calibration 3 see description, page 116
Brake Dly 0.5 s Calibration 4 see description, page 116
Sleep Dly 5 min Calibration 5 see description, page 116
* Current Calib 80 MΩ Calibration 6 see description, page 116
M1 Max Speed 87 % * Calibration 7 see description, page 117
M2 Max Speed 52 % * Calibration 8 see description, page 117
01 Rev. 10/04
118
Controller Troubleshooting
Controller Troubleshooting z Display changes from indicating battery state of

charge to service code indicator whenever im-
proper sequence of operator controls is realized
The System Controller runs diagnostic tests on the in- and when service required condition exists.
tegrity of its internal controls and may recognize when
a problem with external circuitry exists. When diagnos- z Translating indication to a service code number in-
ing a problem, the controller sounds appropriate volves adding the place value of each illuminated
alarms, inhibits proper vehicle functions and displays a segment (A).
service code number. The service code number is lo-
cated in the following pages, the possible causes direct Example
the service technician to the suspected problem area.
z Service Code Numbers can be retrieved through a

light code on the display panel or with the use of a
handset. Both methods are explained later.

z There is a 31 fault service history recorded and
stored by the controller chronologically from last to
first and is retrieved through the use of a handset
only. Vehicle is not disabled during access to serv-
ice history.
z Handset provides the ability to check inputs to the

controller from sensing switches and operator in-
put controls.
z Handset provides the ability to check outputs from

the controller to vehicle mounted devices.
MS-2450-089
Display Troubleshooting Indicators A Segment Place Value

B Wrench Light
z Wrench light (B) blinks when a service required
condition exists on the vehicle.
Display is showing service code (16+4=20) 20.
119
Handset Troubleshooting Aids
MS-2450-044
1 Bus Bar Connections for Power Circuitry

2 Service Terminal Connects to CA402
3 Control Wiring Connects to CA401
z Plug handset into connector CA402 on controller.
MS-2450-043
1 Display Screen
2 DATA INC/DEC Key
Changes value of the parameter indicated by the cursor.
3 Bookmark Keys
Allow you to quickly go back to your favorite selections wit-
hout having to navigate back through the Menu.
4 Menu Navigation Key
left arrows).
z From the main menu, enter the faults menu using

the right arrow on the menu navigation key.
z Select system faults to see the present status of

the unit.
z Select fault history to access this log file. You may

have to scroll through the list using the up and
down arrows.
z Use the monitor menu to monitor switch inputs to

controller and outputs from controller if suspected
as cause.
120
Service Codes z Code information provides the explanation of the

code and a list of possible causes.
The service codes listed in the following pages, are ar- When troubleshooting a problem remember the ability
ranged for ease of locating information needed. of the handset to look at the inputs and outputs of the
controller by using the test mode on the handset. May
z Display information provides what is present on the greatly decrease downtime by isolating a problem to
display of the vehicle. input or output circuitry.
z Handset information provides what is viewed on z Without proper inputs, specific outputs are not pos-
the handset. sible.
z Vehicle information provides alarm status and ve- z An output present but no action would indicate a
hicle status. problem with wiring or component.
121
Service Code 1
BDI Light code
Display information BDI display Always blinking
Wrench Light Off
Handset information Message CODE INPUT
Alarm 1 quick beep

Vehicle information
Effect on vehicle Disabled
Explanation Drive code enabled

Code information
- No drive code input
Possible cause
- Wrong drive code input
Service Code 2
BDI Light code
Display information BDI display Blinking 3 s
Wrench Light Off
Handset information Message THERMAL WARNING
Alarm 2 quick beeps

Vehicle information
Effect on vehicle —
Overtemperature controller, heatsink temperature at 70°C

Explanation
during operation
Code information - Controller dirty
Possible cause
- Poor controller to chassis thermal condition
- Current limit set too high
122
Service Code 3
BDI Light code
Wrench Light Off
Handset information Message MOTOR COVER WARNING
Alarm Repeatedly 1 beep

Vehicle information
Effect on vehicle Traction and lower inhibited
Motor cover is depressed. After fault is cleared, traction con-

Explanation
trol must be returned to netural before traction can be re-
sumed and lower is enabled 4 s after fault is cleared.
Code information
- Weight on motor cover
Possible cause
- Broken wire
- Switch open circuit
Service Code 5
BDI Light code
Display information BDI display Always blinking
Wrench Light Off
Handset information Message — No Known Faults
Alarm 3 quick beeps repeating

Vehicle information
Effect on vehicle No lift possible
Explanation Tilt fault has been received

Code information
- Vehicle on too high a grade and lift height is greater than
Possible cause
20" with gates closed
123
Service Code 6
BDI Light code
Wrench Light Off
Handset information Message — No Known Faults
Alarm 3 quick beeps

Vehicle information
Effect on vehicle — Toggles Drive mode from "Out of Rail" to "In Rail"
Explanation Guided rail aisle has been entered or exited

Code information
- Rail guidance switches actuated or deactuated
Possible cause
Service Code 7
BDI Light code
Wrench Light Off
Handset information Message SRO
Alarm 1 quick beep

Vehicle information
Effect on vehicle No travel allowed
Explanation Static return to off (SRO) during operation

Code information
- Attempted to move vehicle without hands and feet in place
Possible cause
- Open ED-B contact or related circuit wiring
124
Service Code 8
BDI Light code
Display information BDI display —
Wrench Light Off
Handset information Message FRAM WARNING
Alarm 2 quick beeps

Vehicle information
Effect on vehicle — None
Noncritical F-RAM read/write failure in controller F-Ram

Explanation
warning is stored, but not displayed
Code information
- Software failure
Possible cause
Service Code 16
BDI Light code
Display information BDI display Blinking
Wrench Light Blinking
Handset information Message OVERVOLTAGE
Alarm Repeatedly 2 quick beeps

Vehicle information
Effect on vehicle Fast stop with shutdown, or no startup
Explanation Overvoltage on battery
Code information - Overvoltage during operation or at startup > 32.4 V

Possible cause
- Battery condition is bad and charger connected
- Incorrect Batteries or Battery configuration
125
Service Code 17
BDI Light code
Handset information Message THERMAL HIGH

Vehicle information
Effect on vehicle Normal stop with shutdown
Explanation Temperature limit on heatsink exceeded
Code information - Overtemperature > 80°C during operation

Possible cause
- Overtemperature > 70°C at startup
- Excessive load on vehicle
- Improper mounting of controller
Service Code 18
BDI Light code
Handset information Message INHIBIT

Vehicle information
Explanation Function inhibited when chager connected
Code information - Charger connected

Possible cause
- Wire to INHIBIT pin of controller is open
- Charger unit defective
126
Service Code 19
BDI Light code
Handset information Message SRO

Vehicle information
Effect on vehicle — Shall not power up
Explanation Static return to off
Code information - Pots are not in neutral position at startup

Possible cause
- Presence of right or left hand is sensed at startup
- Pots are out of deadband; recalibrate pots
- Defective or miswired presence sensors
Service Code 20
BDI Light code
Handset information Message BRAKE DRIVER OC

Vehicle information
Effect on vehicle Fast stop with shut down
Brake driver overcurrent during operation while brakes ener-

Explanation
gized.
Code information - Too much load connected to the brake output; 2A limit is
Possible cause
exceeded
- Brake output shorted to battery negative
127
Service Code 21
BDI Light code
Handset information Message GATE

Vehicle information
Effect on vehicle Fast stop with shut down
Explanation Gate position fault
Code information - Switches on the gate are not working properly

Possible cause
- GATES OPEN or GATES CLOSED input shorted to bat-
tery negative
Service Code 23
BDI Light code
Handset information Message LOW BATTERY VOLTAGE

Vehicle information
Low battery voltage. When Code 23 is logged, BDI automat-

Explanation
ically resets to 19 %. If this causes the BDI indication to
drop, check setting of Battery Rate in the Controller Settings
Code information section of manual.
- Battery voltage is below 18 V at startup
Possible cause
- Battery voltage is below 15.5 V during operation
- Battery charge available has reached 5 %
128
Service Code 24
BDI Light code
Handset information Message LEFT MOTOR OPEN

Vehicle information
Effect on vehicle Shall not Power Up
Explanation Left motor open circuit at Power Up

Code information
- Wiring to the left motor is open
Possible cause
- Left motor is defective
Service Code 25
BDI Light code
Handset information Message RIGHT MOTOR OPEN

Vehicle information
Effect on vehicle Shall not Power Up
Explanation Right motor open circuit at Power Up

Code information
- Wiring to the right motor is open
Possible cause
- Right motor is defective
129
Service Code 26
BDI Light code
Handset information Message C/L

Vehicle information
Effect on vehicle Fast stop with shutdown
Explanation Motor current limiting fault
Code information - Excessive load on vehicle

Possible cause
- Motor shorted
- Controller failure (if it occurs frequently)
Service Code 27
BDI Light code
Handset information Message HARDWARE FAILSAFE 1

Vehicle information
Explanation Controller hardware failure

Code information
- Controller failure
Possible cause
130
Service Code 28
BDI Light code
Handset information Message CONFIG LOST

Vehicle information
Explanation Configuration parameters are corrupted

Code information
- Controller failure (if not cleared after executing FACTORY
Possible cause
VALUES)
Service Code 29
BDI Light code
Handset information Message MAIN CONT FAULT

Vehicle information
Effect on vehicle — Shall not Power Up
Explanation Main contactor fault (ED contactor fault)
- Battery positive wire is open on controller busbar X4

Possible cause
Code information - Main contactor (ED contactor) is not closing
- Main contactor (ED contactor) is welded
- ED COIL output of controller open or shorted to battery
negative or battery positive
- Fu2 blown
131
Service Code 30
BDI Light code
Handset information Message CURRENT MEASURE

Vehicle information
Effect on vehicle — Shut down
Explanation Current measurement circuit is out of range

Code information
- Controller Failure
Possible cause
Service Code 31
BDI Light code
Handset information Message HARDWARE FAILSAFE 2

Vehicle information
Explanation Hardware failure

Code information
- Communications or controller board failure
Possible cause
- Poor connection at CA401
132
Service Code 32
BDI Light code
Display information BDI display —
Handset information Message MOTOR STALL

Vehicle information
Effect on vehicle Shutdown
Explanation Both motors stalled for 15 seconds

Code information
- Obstruction
Possible cause
Service Code 34
BDI Light code
Handset information Message FRAM FAULT

Vehicle information
Explanation Data in the nonvolatile parameter store is corrupted

Code information
Possible cause
133
Service Code 35
BDI Light code
Handset information Message SFW

Vehicle information
Explanation Controller software failure

Code information
- Controller (software) failure. Try to restart (power up)
Possible cause
again
Service Code 36
BDI Light code
Handset information Message MAIN CONT DRVR

Vehicle information
Effect on vehicle — Shall not Power-up
Explanation Main contactor driver
Code information - Controller failure

Possible cause
- Miswiring in ED Circuit
- Failed ED Contactor
134
Service Code 37
BDI Light code
Handset information Message DRIVE THROTTLE

Vehicle information
Explanation Steer Throttle Fault
Code information - Steering potentiometer is misadjusted; recalibration

Possible cause
needed
- Open or shorted wire(s) on steering potentiometer
Service Code 38
BDI Light code
Handset information Message STEER THROTTLE

Vehicle information
Explanation Steer Throttle Fault
Code information - Steering potentiometer is misadjusted; recalibration

Possible cause
needed
- Open or shorted wire(s) on steering potentiometer
135
Service Code 39
BDI Light code
Handset information Message MOTOR SHORT

Vehicle information
Effect on vehicle — Shutdown
Explanation Motor short fault
- Motor is shorted
Possible cause
Code information - Busbar connections battery negative and battery positive
on controller are wired backwards
- Open ED Contacts
- Shorted Lift Solenoid Contacts
Service Code 40
BDI Light code
Handset information Message LEFT POWER FAULT

Vehicle information
Effect on vehicle — Shall not Power Up
Explanation Left power fault at Power Up

Code information
- One motor lead of left motor is shorted to battery positive
Possible cause
136
Service Code 41
BDI Light code
Handset information Message RIGHT POWER FAULT

Vehicle information
Effect on vehicle — Shall not Power up
Explanation Right power fault at Power up

Code information
- One motor lead of right motor is shorted to battery positive
Possible cause
Service Code 42
BDI Light code
Handset information Message PRESENCE SENSOR

Vehicle information
Explanation Presence sensor fault
- Too much daylight on the receiver of the left or right pres-

Possible cause
Code information ence sensor
- Open circuit in the wiring of the left or right LED's Short
circuit in receiver of the left or right presence sensor
- Short circuit to battery positive on the receiver input (emit-
ter) of the left or right presence sensor
137
Service Code 43, 44
BDI Light code

or
Display information
BDI display Blinking
Handset information Message CAN

Vehicle information
Explanation Communication fault
Code information - Open or short circuit on communication lines

Possible cause
- Short circuit to battery positive on communication lines
- Faulty Display or Controller
Service Code 45
BDI Light code
Handset information Message MOTOR SHORT

Vehicle information
Explanation Motor short fault
Code information - Short circuit from motor lead to motor lead

Possible cause
- Short circuit from motor lead to battery positive or battery
negative
138
Service Code 49
BDI Light code
Handset information Message THERMAL LOW

Vehicle information
Heatsink less than 10°F (-12°C) during operation or at power

Explanation
up
Code information
- Trying to operate vehicle at a temperature below the cold
Possible cause
temperature limit 10° F (-12° C)
Service Code 50
BDI Light code
Display information BDI display Blinking or static
Wrench Light Blinking or static
Handset information Message BRAKE FAULT
Alarm Repeatedly 2 quick beeps or nothing

Vehicle information
Explanation Brake fault

Code information
- Wiring of brake is open or shorted to battery positive
Possible cause
139
Service Code 128
BDI Light code
Handset information Message — CAN
Alarm Repeatedly cracking

Vehicle information
Explanation No Watchdog Trigger Signal

Code information
- Controller or Display Failure
Possible cause
Service Code 136
BDI Light code

Vehicle information
Effect on vehicle Fast stop with shutdown or no power up
Explanation No messages received
- Unexpected failure of controller software. Try to restart

Code information Possible cause
(power up) again
- Open or short circuit on communication lines
- Display or controller Failure
140
Service Code 160
BDI Light code

Vehicle information
Explanation Unexpected SFW interrupt
Code information - Unexpected failure of communication board software.

Possible cause
Try to restart (power up) again
- Display or controller failure
Service Code 192
BDI Light code

Vehicle information
Explanation —
Code information - Unexpected failure of controller software. Try to restart

Possible cause
(power up) again
- Open or short circuit on communication lines
141
Hydraulic Interaction
Hydraulic Interaction z ED-A closes supplying current to P1 contact. ED-B

closes supplying current to ECS.
This information describes the electrical system and z ECS in platform position supplies current to DMSL
hydraulic system interaction for the various hydraulic and DMSR.
functions of the vehicle.
z With operator in position, DMSL and DMSR are
closed completing current path to RAS1 and
Static Condition LOS1.
Static Condition means the operator is in position with z The operators hands must be in position on grips
key on and no hydraulic functions being requested. to provide proper input signals from RHS and LHS.
This condition is necessary before any hydraulic func-
tions will operate. z Since P1 is not energized to start the pump motor
and SV1 is not energized, the check valves will
z DTS in drive position supplying current to KYS. keep hydraulic oil from flowing back to the reser-
voir maintaining platform height.
z KYS cycled to on supplying power to display and
MRC1. EDS1 and EDS2 closed allowing ED to en-
ergize.
03 Rev. 7/04
142
6116-02
03 Rev. 7/04
143
Platform Raise z Hydraulic pressure then unseats check valve 1 and

flow continues through the velocity fuse and to the
cylinder.
Platform Raise occurs when static conditions are met
and the operator requests the lift function by actuating z The cylinder extends and platform raises.
the raise button.
z When platform reaches 510 mm (20 in) of lift
z RAS1 closes providing a current path to RCS. height, as detected by HTS20, the raise function
will stop unless GOSL and GOSR are open and
z When platform is not at the raise cutout position, GCSL and GCSR are closed indicating the plat-
RCS will be closed completing the current path to form gates are fully closed.
P1 contactor coil.
z If pressures in the hydraulic system exceed the
z When the controller does not have any restrictions setting of RV1, the port of the valve is forced open
or service conditions preventing raise (e.g. control- and relieves pressure by dumping to the reservoir.
ler failure, battery charger plugged in etc.), the con- When pressure drops, the valve closes.
troller will close the current path to battery nega-
tive, energizing P1 coil. z Check valve 2, under hydraulic pressure unseats,
however the check valve in SV1 remains seated
z With P1 coil energized, contact P1 closes complet- and blocks flow to the reservoir.
ing the current path to the pump motor.
z The pump motor starting turns the pump and be-

gins to produce pressure.
03 Rev. 7/04
144
6117-02
03 Rev. 7/04
145
Platform Lower z Hydraulic pressure from the weight of the platform

on the cylinder keeps check valve 1 seated. This
pressure does unseat check valve 2 allowing flow
Platform Lower occurs when static conditions are met to SV1.
and the operator requests lower by actuating the lower
button. z Since the check valve in SV1 was replaced with
free flow, flow continues to the flow control valve
z LOS1 closes providing current path to CHSL and and on to the reservoir.
CHSR.
z The flow control valve limits the hydraulic flow to
z MRC1 controller providing current path to FLMCS, provide a controlled decent of the platform.
RLMCS, RRMCS and FRMCS.
z If a hose were to break, bypassing the flow control
z When the lift chain is not slack, CHSL and CHSR valve, the high volume flow through the velocity
are closed and allow current flow. fuse at the cylinder will move the valve from free
flow to flow block thus preventing uncontrolled de-
z When the controller does not have any restrictions cent.
or service conditions preventing lower (e.g. con-
troller failure, vehicle monitoring switches open z When the lower button is released, causing SV1
etc.), the controller will close the current path to check valve to again block flow, the hydraulic pres-
battery negative, energizing SV1. sure increase caused by this sudden change is
dampened by the accumulator.
z When SV1 is energized, the valve moves and re-
places the check valve with free flow.
03 Rev. 7/04
146
6118-02
03 Rev. 7/04
147
Tilt Sensor
Tilt Sensor z Adjust the three nuts (5) on top of tilt sensor (3)
until center bubble (2) is centered in inner circle.
z Nuts (5) should be adjusted until one or two nut

threads (4) of bolt are visible above the nuts (5).
z Power up vehicle and connect handset.
z Verify green LED on bottom of tilt sensor TLTS (3)

is "on".
z With gates open, raise platform until the 510 mm

(20 in) switch is activated.
z Close gates and drive vehicle, load deck first, up a

4.5° (7.8 % grade) incline.
z Center bubble (2) on tilt sensor TLTS (3) should be

completely outside the outer circle in this position.
z After a three second delay, an alarm should sound,

three quick beeps repeatedly and fault code 5
(00000X0X) should be displayed.
MS-2450-084
z Verify that the red LED on the bottom of the tilt sen-
1 Contactor Panel sor TLTS (3) is "on".
2 Center Bubble
3 Tilt Sensor (TLTS) z Lower platform, alarm should stop and fault code
4 Nut Threads clears.
5 Nut
z Raise platform while still on incline and verify that
lift is inhibited, alarm sounds, fault code 5 is dis-
The tilt sensor TLTS (3) is located on the contactor played and red LED is "on", on bottom of tilt sensor
panel (1). The purpose of the tilt sensor TLTS (3) is to TLTS (3).
inhibit lift when the 2100 mm (84 in) vehicle is on an
incline of 4.5° (7.8 % grade) or more and when the z Lower platform completely and back vehicle off of
3000 mm (118 in) vehicle is on an incline of 1.5° (2.6 % incline.
grade) or more.
z Disconnect handset and install load deck.
Alignment
z Park vehicle on level, dry concrete surface.
z Remove load deck to expose tilt sensor TLTS (3).
02 Rev. 4/05
148
Contactor
Contactor Contacts
Contactor ED (Emergency Discon-

nect) 24 V
The purpose of these instructions is to instruct the user

on proper care and maintenance to obtain satisfactory
service from these devices. Crown has tested and ap-
plied these contactors according to the requirements of
our vehicle. No modifications or changes should be
made in the layout, physical arrangement or electrical
connections without permission from Crown.
Caution! Risk of property damage

or injury!
MS-2450-079
Before any inspection, adjust-
ments, servicing, parts replace-
7 Contact Tip
ment or any other act is per-
formed requiring physical
contact with the electrical work-
z In normal operation, the contacts (2, 3) will become
ing components or wiring of
blackened, discolored and roughened. This will not
these contactors, disconnect
interfere with proper operation and cleaning is not
battery, raise drive wheels clear
necessary.
of floor and place blocks under
vehicle frame.
z Check the condition of each contact tip (7). Look
for excessive pitting or deformities that could
Inspection cause intermittent operation. Silver contact facing
may transfer to either the moving or fixed contact
(2,3) and cause buildup on one contact. The con-
The following information is intended to assist during tacts should be replaced before the silver contact
periods of normal maintenance and to provide checks facing is completely eroded through to the backing
for maintaining adjustments. As these devices are material. Do not file tips. Filing will effect proper op-
tested and adjusted at the factory, they should not nor- eration by deforming the convex shape of the tip.
mally require further adjustments. However, if factory
adjustments are tampered with or otherwise changed, z Contacts should always be replaced in pairs.
the checks contained in the following information may
be made.
Coil
z Remove all electrical connections.
z Resistance reading of the coil should be between

50-55 Ω.
z If reading does not fall within the limits, replace the

coil.
01 Rev. 3/01
149
Contactor
Component Replacement z Remove electrical connections to contacts. Coils

(5) do not have to be disconnected for this proce-
dure.
Contact Replacement
z Remove two screws (1) from top of cover (6) and
lift cover (6) assembly from vehicle.
z Disassemble and replace contacts (2, 3).
z Place cover (6) assembly on coils (5) and fasten

securely.
z Connect cables.
MS-2450-085
1 Screw
2 Contact (fixed)
3 Contact (movable)
4 Plunger
5 Coil
6 Cover
01 Rev. 3/01
150
Contactor
Coil Replacement z Disconnect all electrical wiring.
z Disassemble mounting bracket (1) from contactor

panel (2) and lift entire contactor (3) and mounting
bracket (1) from vehicle.
z Disassemble mounting bracket (1) from

contactor (3).
z Remove two screws from cover (4) and separate

cover assembly from coil (5).
z Transfer plunger from existing coil (5) to replace-

ment coil.
z Reassemble cover (4) assembly (4) to coil (5).
z Assemble mounting bracket (1) to contactor (3).
z Mount contactor (3) and mounting bracket (1) on

contactor panel (2) and reconnect all electrical wir-
ing.
MS-2450-086
1 Mounting Bracket
2 Contactor Panel
3 Contactor
4 Cover
5 Coil
01 Rev. 3/01
151
Battery
Battery Throughout the industrial sector, it is widely accepted

that the optimum point of recharge for industrial batter-
ies when a battery charge level of 20 % remains. Re-
charging at this level is pivotal to ensure proper re-
Battery Discharge Indicator, charge and maximum battery life.
Lift Interrupt
Battery capacity is directly affected by duty cycle. The
slower the batteries are discharged, the more total
amp-hours are available. Therefore, it is difficult to
measure battery discharge, not to mention how to gage
when a battery is 80 % discharged. To compensate for
the various duty cycles, the WAV allows for a BDI rate
adjustment.
Adjustment range is 1 to 15, has been designed to

work over all anticipated WAV duty cycles:
– 1 = harshest duty
– 15 = lightest duty
WAV batteries, during periods of use, are approxi-

mately 80 % discharged when battery voltage reads
22.7 V with batteries disconnected. Batteries beyond
MS-2450-087
this voltage will discharge rather quickly (battery is
nearly discharged).
1 Battery Discharge Indicator (BDI), Lift Interrupt
on Display Panel
The system controller has been configured so that an
2 Steering Pod
average duty cycle, battery setting 7, the battery level
would be approximately 20 % when battery voltage
The battery discharge indicator/lift interrupt on display reaches 22.7 V with batteries disconnected.
panel (1) shows the state-of-charge of the battery.
When the battery is at "FULL" charge, all segments will The following benefits are realized when the actual
be "ON". The battery symbol is yellow in color and all duty cycle is matched to the correct battery rate setting:
other segments are green. As the battery discharges, – Maximum power is removed from batteries be-
one segment at a time will turn "OFF". Eventually, only fore recharging.
the battery symbol will be "ON" indicating an approxi-
mate 20 % charge remaining. The battery symbol will – Maximum efficiency in recharging occurs.
also flash when an approximate 20 % charge remains.
This is a warning to the operator to recharge batteries. – Maximum life for batteries is achieved.
If the truck is continued in operation without recharging – Low voltage conditions (fault code 23) are elim-
batteries, the electronic control will not allow the plat-
inated.
form to be raised.
02 Rev. 12/04
152
Battery
Recommendation 1: Battery
A battery rate setting of 7 should be utilized as the de-
fault or starting point for all applications, regardless of
battery type or size.
Recommendation 2:
If vehicle is regularly experiencing low voltage condi-

tions (fault 23), battery rate should be decreased by
one to six.
Continue to decrease battery rate until low voltage

faults are minimal. Also check battery voltage when the MS-2450-088
BDI reads 20 % remaining charge. It should be approx-
imately 22.7 V. WAVE® vehicles are equipped with four 6 V mainte-
nance free batteries.
Battery voltage is normally less than 22.7 V when fault
23 occurs.
Recommendation 3:
If vehicle battery voltage appears to run out prema-

turely, the battery rate setting should be increased by
one to 8. Continue to increase battery rate until the bat-
tery voltage is 22.7 V at a BDI reading of 20 % remain-
ing charge. If low voltage faults are encountered, you
have gone too far, decrease one number.
02 Rev. 12/04
153
Battery
Safety Rules Inspection
z Check for corroded terminals, cracks and intercon-

Warning! Risk of arcing! necting cable connections.
Do not lay metallic or conduc-
z Inspect battery for excessive moisture.
tive objects on battery. Other-
wise arcing will result and
cause property damage. Cleaning
z Do not allow dirt, cleaning solution or other foreign
Always keep vent plugs tightly in place when cleaning
material to enter cells. Impurities in electrolyte has
battery. When properly charged, the battery will remain
a neutralizing effect reducing available charge.
clean and dry. All that is necessary is to brush or blow
off any dust or dirt which may accumulate on them.
z If battery repair is planned, follow the battery man-
ufacturer's instructions concerning repair practices
and procedures. Maintenance Free Batteries
z Do not touch non-insulated parts of DC output con-
Sealed Maintenance Free Batteries contain a pressure
nector or battery terminals to avoid possible elec-
release valve and under normal operating conditions
trical shock.
do not require any special ventilation.
z Disconnect all AC and DC power connections be-
fore servicing the charger. Warning! Risk of property damage!
z Charger is NOT for outdoor use. Do not expose Do not try to open this battery or
charger to rain or snow or charge a frozen battery. remove the pressure release
valve.
z Charger is designed to charge lead acid batteries
ONLY. Attempting to charge dry-cell batteries may In these batteries, the sulfuric acid is absorbed within a
cause them to burst and result in personal injuries glass separator, which acts like a sponge, and the gas-
and property damage. ses generated while on charge are recombined. Only
under severe overcharging, such as connected to an
z Do not use charger if it has been dropped or other- improperly sized charger, will any significant amount of
wise damaged. gasses be released from the battery. Also, being a
valve regulated battery, it never requires watering.
z If battery repair is planned, follow the battery man-
ufacturer's instructions concerning repair practices
and procedures.
02 Rev. 12/04
154
Battery
Charger The battery charger features an automatic start/stop

charge cycle which will cause less battery damage re-
sulting from over/under charging.
Before charging, remove deck and set the charger is

set to the correct type of battery through the wet/sealed
switch (3) wet or sealed (maintenance free).
Improper charger battery set-

ting may damage batteries.
Make sure you have set the
charger to the correct type of
battery before charging.
Charging Requirements
MS-2450-083 Charging requirements will vary depending on vehicle

use.
1 Circuit Breaker Reset
2 Inhibit Line Fuse The chart below lists the approximate charging time re-
3 Wet/Sealed Switch quired to fully charge a battery after discharging battery
4 Charger LED (4-A, 4-B)
to 80 % of full capacity, assuming a 6 h discharge rate.
5 Battery Charge LED (5-A, 5-B, 5-C)
Battery Charging time, 25 A charger
195 A/h, 10 h
Maintenance Free
02 Rev. 12/04
155
Battery
Charging LED on charger
LED Color Meaning
4-A Yellow Charger on

4-B Red Abnormal cycle
5-A Green Charge complete
5-B Yellow 80 % charge
5-C Red Incomplete (See In-
formation below)
MS-2450-081
1 LED on Service Panel

Information
This LED also flashes when sea-
To monitor charging status, refer to the three LED's on led/maintenance free battery is
the service panel (1) and/or the five LED's on charger
selected
(See Illustration MS-2450-083).
z To charge batteries, plug charger into a 220 V,
LED on service panel 10 A (minimum) AC outlet.
z Charger will go through a diagnostic self-test. All

LED Color Meaning LED's will flash 3 times, then each LED will flash
individually.
1-A Red Abnormal
1-B Yellow Charging z After a three to five second delay the charger will
turn on. Both the yellow "Charger On" (4-A) and
1-C Green Charge complete red "Incomplete" (5-C) LED will illuminate. A flash-
ing red "Incomplete" LED (5-C) prior to the yellow
"80 % Charge" LED (5-B) illuminating indicates
sealed (maintenance free) batteries have been se-
lected. Be sure this is the correct selection.
z When battery voltages reach 2.35 to 2.38 V per

cell, the yellow LED "80 % Charge" (5-B) will illumi-
nate.
z When a charge cycle is terminated, both the yellow

"80 % Charge" (5-B) and the yellow "Charger On"
LED (4-A) will turn off. The green "Complete" LED
will then illuminate (5-A).
To stop the charger at anytime during charging, unplug

charger.
02 Rev. 12/04
156
Battery
Abnormal Charge Sequence z Turn charger "off" and measure the battery volt-
age. Should be 25.3 V to 26.0 V.
If for any reason charging is not complete within 16 to
20 h or if an over-current condition occurs, the "red" z Measure and record the voltage across each bat-
LED (5-C) will illuminate. Unplug charger to clear and tery. Each battery should be between 6.3 V and
plug-in charger again to restart. 6.5 V.
If shorted battery cells are detected during a charge cy- z Replace any battery that measures less than
cle, the "red" LED (5-C) will flash on for 2 s and off for 6.0 V. If there are batteries which are 0.3 V lower
1 s. than associated batteries, the batteries could be
showing signs of undercharging.
Battery Testing z Return vehicle to service.
Following is a testing procedure for verifying the integ-

rity of the batteries.
z Fully charge batteries.
z After charge is complete, again, plug-in charger.

The 80 % charge LED (5-B) on the battery charger
should come "on" within 5 min Measure the overall
battery voltage while charger is "on". Should be
greater than 28.2 V.
If the 80 % charge light (5-B) does not come "on",
continue charging until light comes "on".
If the abnormal light (4-B) comes "on", the charger
is malfunctioning and should be replaced.
02 Rev. 12/04
157
Battery
Troubleshooting
Symptom Probable Cause Remedy
Charger will not turn "ON" - AC circuit breaker is open at circuit - Check for AC voltage, close.
Does not go thru self-test breaker panel - Reset circuit breaker.
- AC circuit breaker is open on charger
Charger will not turn "ON" - Charger is not connected to battery - Connect battery to charger.
after self-test - Incorrect plug polarity between charger - Connect plugs according to polarity.
and battery
Charger cycling between - AC Voltage to charger is low - Check for proper AC voltage
"ON and "OFF" - Low charging current - Battery and charger voltage do not
match. Battery voltage is too high.
Make sure charger and battery voltage
are properly matched. Reconnect bat-
tery to charger to reset voltage read-
ings.
Red abnormal LED flashes - Output current is too high due to sud- - Remove short circuit condition. Unplug
den short at charger charger to clear flashing LED and plug-
in charger again to restart.
RED abnormal LED stays - Battery not fully charged - Battery disconnected from charger be-
"ON" fore charge cycle was complete.
- Battery and charger voltage doesn’t - Match correct battery voltage to
match charger voltage.
- Shorted battery cell(s) - Check battery for open or shorted bat-
tery cells.
- Broken or loose battery and charger - Check for continuity. Tighten battery to
connection charger connections and restart charge
cycle.
Decreased run time - Battery failure - Test batteries as described in Battery
Testing.
- Insufficient charge time - Allow enough charging time (see
Charging Requirements, page 155) for
batteries to reach full charge.
01 Rev. 3/01
158
Motors
Motors z Inspect the brush springs for signs of heating that

may change the tension of the brushes on the com-
mutator. With brushes in place, be sure the spring
and brush pigtails do not interfere with the brush
Inspection movement through its usable length.
Risk of property damage or z Check motor for shorts between terminals and mo-
Warning! tor frame by use of an ohmmeter on a high resist-
severe injury!
ance scale such as R x 10,000. If a reading of less
Unauthorised component re-
than 50,000 Ω is observed, the source of trouble
moval or improper maintenance
should be repaired before unit is placed into oper-
can result in significant danger
ation to prevent further damage.
to the user.
Only qualified and experienced
personnel should perform Traction Motor
maintenance and repair on bat-
teries.
Disconnect battery before in- Removal
specting motor.
z Raise platform to a height that permits easy access
When inspecting the traction and pump motors, be to traction motor.
sure to include the following:
z Block platform.
z Check that connecting cables are not worn, dam-
aged and are secure at motor terminals. z Remove load deck cover and disconnect battery.
z Check commutator for any discoloration that may z Remove rear access covers.
show signs of raised bars or stalls. If it is glazed or
dirty, clean with a strip of No. 00 sandpaper. Blow z Remove "H" frame (3 pieces).
out all dirt and grit with low pressure compressed
air. z Disconnect electrical connections from motor/
brake.
z Check brushes for chips, breaks or oil-saturation. If
any of these conditions exist, the brushes must be z Remove the 4 motor mounting bolts. Remove mo-
replaced. If brushes are dirty, clean with a dry tor from truck.
cloth. Be sure the bushes slide freely in their hold-
ers and make full contact with the commutator.
Brushes that are worn beyond one-half their origi- Brush and Spring Removal
nal length should be replaced.
z Refer to Traction Motor Removal and remove mo-
– Replace traction motor brushes when they
tor.
reach a length of 8 mm (0.295 in).
z Using flatblade screwdriver, remove brush caps.
– Replace lift pump motor brushes when they
reach a length of 9 mm (0.34 in).
z Lift brush and spring assembly from motor.
02 Rev. 3/01
159
Motors
Lift Pump Motor Current Readings
Current readings should be taken under the following

Removal conditions:
z Remove front chassis cover and disconnect bat- z Travel-empty; take reading at full travel speed.
tery. Current should measure 6 to 12 A per motor.
z Remove power cable from motor. Remove all nuts z Lift-empty; take reading while raising. Should
and washers from motor terminals. measure 80 to 90 A.
z Remove the two, top motor mounting screws.
z Note position of motor on unit. Lift motor from unit.
Brush and Spring Removal
z Refer to Lift Motor Removal and remove motor

from hydraulic unit.
z Remove remaining power cable and all nuts and

washers from motor terminals.
z Push field coil terminals through commutator cover

and remove cover.
z Remove brush lead screws.
z Remove brush and spring assembly.
02 Rev. 3/01
160
Service Panel
Service Panel
MS-2450-080
1 Push/Drive Switch-DTS 5 A.C. Inlet Connector-CA405

2 Elevation Control Switch-ECS 6 Hour Meter-HM
3 Emergency Disconnect Switch-EDS2 7 LED
4 Emergency Raise/Lower Switch-ERLS 8 Fuse-FU1
A.C. inlet connector - CA405 Check extension cord:
Provided so charger can be plugged into a 220 V, 10 A z The extension cord plug pins must be the same
(minimum) AC outlet. number, size and shape as the charger inlet plug.
Locate cord so it will not be stepped on, tripped over, z Check extension cord wiring and condition.
or otherwise subject to damage or stress.
z Be sure wire size can safely handle load.
01 Rev. 3/01
161
Service Panel
Charger LEDs Pushing or towing speed must not exceed 3.2 km/h to
prevent damage to the controller. The drive motors are
Three LED (7) are provided to monitor charging status. permanent magnet motors and when the vehicle is
When the charger is initially "plugged-in", it will perform pushed or towed will act as generators.
a diagnostic self-test. All three LED's (7) will flash 3
times, then each LED (7) will flash individually. After a
3 to 5 s delay, the charger will turn "ON" and the yellow, Warning! Risk of destruction!
charging LED (7) will illuminate. After charging is com-
If vehicle is pushed or towed in
plete the yellow, charging LED (7) will turn "OFF" and
excess of 3.2 km/h, enough cur-
the green, charge complete LED (7) will turn "ON".
rent may be generated to de-
stroy the controller.
If for any reason charging is not complete within 16 to
20 h or if an over-current condition occurs, the red, ab-
If pushing or towing is to exceed 3.2 km/h, disconnect
normal LED (7) will illuminate. Unplug charger to clear
motor connectors CA601 and CA602. For normal oper-
and plug-in charger again to restart.
ation, the switch (1) must be returned to the "Drive' po-
sition. This switch (1) does not require adjustment.
If shorted battery cells are detected during a charge cy-
cle, the red, abnormal LED (7) will flash on for 2 s and
off for 1 s. For additional information, see Battery, Warning! Risk of injury!
page 152.
Vehicle does not have brakes,
Push/drive switch - DTS steering or travel control when
switch is in "Push" position.
Do not push vehicle while oper-
When this switch (1) is in the "Drive" position, normal
ator is on platform.
operation of steering and traction is possible.
z If the vehicle must be pushed or towed, place Elevation Control Switch - ECS
switch (1) in the "Push" position to electrically re-
lease brakes. Traction, steering and lift/lower is z For activating the raise/lower switch ERLS (4) on
disabled at this time. the service panel, place the elevation control
switch (2) in the "Base" position.
The emergency raise/lower switch-ERLS (4) on the

service panel is active. Platform raise, lower switches
and steer/traction pots are disabled at this time.
Traction, steering, lifting and lowering is not possible

with switch (2) at base position.
z For normal operation, return switch (2) to the 'Plat-

form" position. This switch (2) does not require ad-
justment.
01 Rev. 3/01
162
Service Panel
Emergency Disconnect Switch - EDS2 Emergency Raise/Lower Switch - ERLS
z Push the button to depress the Emergency Discon- z Put the elevation control switch-ECS (2) is in the
nect Switch - EDS2 (3) plunger. "Base" position to control platform raise and lower
with this switch (2).
Power is removed from the emergency disconnect
contactor coil which opens its contact and removes This switch (2) does not require adjustment.
power from the lift, lower and traction circuit.
Fuse - FU1
z To power vehicles backup, twist switch to reset.
Fuse-FU1 (8) is the control fuse. If it fails, the truck can
z The keyswitch must then be cycled "OFF" and not be powered up.
back to "ON".
z Replace with an ABC-15 A Fuse. Also see Fuses,
This switch requires no adjustment. Also see Switches, page 82.
page 73.
Hour Meter - HM
The Hour Meter-HM (6) is used to accurately record the

operator in position time (feet on brake release pedals).
This instrument serves as an aid in determining a lubri-
cation and maintenance schedule.
01 Rev. 3/01
163
Notice:
Printed in Germany
164
BRAKE MAINTENANCE
Printed in Germany
165
BRAKE MAINTENANCE
Notice:
Printed in Germany
166
BRAKE MAINTENANCE
Brake System
Brake System Adjustment for electronic braking is deceleration rate.

Settings and procedures for making these adjustments
are in the controller settings section of this manual.
Parking brake
The parking brake consists of a 12 V electric brake at-

tached to each drive motor and energized by the sys-
tem controller.
When the operator depresses the switches DMSR and

DMSL, and engages the hand presence sensors LHS
and RHS, and applies an input to the system controller,
power will then be supplied to the brake. The brake is
electromagnetically released and the vehicle is free to
travel.
6121
When the operator releases any of the four interlocks,
Two types of electronic braking are used on the vehi-
the system controller will electronically brake the vehi-
cle. At higher speeds, regenerative braking is used and
cle to a stop. One half second after the calculated stop,
at lower speeds, active braking. When the traction con-
the parking brake coil will de-energize. Springs will
trol twist grip is placed in neutral or the opposite travel
force armatures within the brake to press the brake
direction, the system controller goes into the electronic
pads against the rotor, applying the parking brake.
braking mode.
The only situation when the parking brake is applied
Regenerative Braking before the calculated stop time has elapsed is when
the emergency disconnect is used or when a major
fault with the system controller occurs.
When in the electronic braking mode, the motors act as
generators driven by the inertia of the vehicle. When
the generated voltage is greater than battery voltage,
the system controller places the battery in series with
the motors. The battery receives a charge from this and
provides an electrical load on the motors causing them
to slow down. When vehicle speed slows to the point
that the generated voltage is less than battery voltage,
the vehicle switches to active braking.
04 Rev. 3/01
167
BRAKE MAINTENANCE
Brake System
Parking Brake Wear z Using a feeler gauge, make sure air gap (A) does
not exceed 0.25 mm (0.010 in). Wear in excess of
this requires replacement of the brake.
z Brake is not adjustable.
Stopping Distance
z Maximum stopping distance of the vehicle on a

level, smooth, dry concrete surface is 1270-
1780 mm (50 - 70 in) with load deck and tray
empty, traveling in the load deck first direction and
at top speed of 6 km/h (4 mph), (with platform less
than 510 mm [20 in], gates open, in Rabbit Mode,
lift foot). This is not for parking brake assisted
MS-2450-045 stops.
1 Coil Body z To adjust stopping distance refer to "Decel Rate" in

2 Armature Plate the controller settings section of this manual.
z Decreasing the value of this setting increases de-

A Air Gap
celeration force and shortens stopping distance.
The parking brake is not normally applied when the ve- z If stopping distance cannot be achieved due to ap-
hicle is moving so wear will be minimal. plication conditions, reduce the maximum allowa-
ble speed (refer to Max Speed in controller settings
If there is question of the brakes functionality, the air section) until stopping distance can be brought into
gap (A) should be checked. acceptable range.
Information
Measure the air gap (A) between
coil body (1) and armature plate
(2) when brake is applied and no
power is supplied.
04 Rev. 3/01
168
MAST MAINTENANCE
Printed in Germany
169
MAST MAINTENANCE
MS-2450-046
– right visible mast side = right

– left visible mast side = rear
04 Rev. 10/04
170
MAST MAINTENANCE
1 First Stage Mast 17 Guide

2 Guide 18 Guide
3 Guide 21 Third Stage Mast
4 Guide 22 Mast Cap
5 Shim 23 Screw
7 Guide 24 Screw
8 Guide 25 Chain Anchor
9 Shim 26 Chain Anchor Fixation Screw
11 Guide 27 Cable Clamp
12 Second Stage Mast 29 Wire Harness Plug
13 Guide 30 Yoke
14 Guide
15 Guide A Strap Placement for Third Stage Mast
16 Guide B 1.3 mm (0.050 in) Land
Torque Requirements z Hoist and block platform using a hardwood block.
z The two 3/8 in diameter screws (24) that secure Danger! Risk of trapping and severing
the yoke (30) to the second stage mast (12) must limbs!
be tightened to 36.5-50.5 Nm (27-37 ft.lb). An unsecured mast and attach-
z The two 3/8 in diameter screws (26) that hold the cause fatal injuries. Always
chain anchor (25) on the second stage mast (12) block mast when working on ve-
must be tightened to 36.5-50.5 Nm (27-37 ft.lb). hicle with mast in elevated posi-
tion, even though connected to
a hoist.
Mast Disassembly
z Unplug wire harnesses and remove cable clamps
Refer to Illustration MS-2450-046. (27) on either side of third stage mast (21) at plat-
form bottom.
z Lower platform completely, turn key switch off and
disconnect batteries. z Pull wire harnesses and wire harnesses plugs (29)
through holes in bottom right and left hand side of
z Attach straps to hoist and platform as shown in A. third stage mast (21).
z Unplug connector for DMSR and DMSL switches z Remove guides (16, 18) and shims (9) from front
located below floorboard. Remove floor board and and right side of third stage mast (21).
mast cap (22).
z Remove guides (14, 15, 17) from rear and left side
of third stage mast (21).
04 Rev. 10/04
171
MAST MAINTENANCE
z Unfasten chain anchor (25) from third stage mast Mast Maintenance
(21).
z Hoist platform off of truck being careful not to pinch Refer to Illustration MS-2450-046.
the control cables and cut them.
z Clean outside of first stage mast (1), inside and
z Remove all shims (5) from top of first stage mast outside of second stage mast (12), and inside of
(1) and second stage mast (12). third stage mast (21) with a shop rag to remove dirt
and grease.
z Remove guides (11, 13) from top of second stage
mast (12). Move wire harnesses to rear of second z Apply grease (063002-024) to top 150-200 mm
stage mast (12), unloop chain from pulley and (6–8 in) of the inside four corners of second stage
place it in the rear of chassis, being careful not to mast (12) and third stage mast (21).
kink it.
z Inspect Guides for wear.
z Remove hydraulic line and velocity fuse from base
of lift cylinder being careful to catch any hydraulic When new they have a 1.3 mm (0.050 in) land (B) built
oil that runs out. in to indicate wear. If the land (B) is worn away to the
groove or if the guide surfaces have deep grooves in
z Remove two screws ( 24) that mount lift cylinder them, the guide has to be replaced.
and yoke (30) to second stage mast (12).
Mast Assembly
z Carefully remove lift cylinder and yoke (30) by lift-
ing it out the top of the first stage mast (1).
z Install guides (2, 3, 4) back onto first stage
z Use hoist and strap to lift and block second stage mast (1).
mast (12) using a hardwood block.
z Do not install any shims at this time.
z Remove guides (7) and shims ( 8, 9) from bottom
right and rear of second stage mast (12). z Place control cables inside first stage mast tube to
protect them from being cut.
z Remove guides (7) from bottom front and left side
of second stage mast (12). z Use hoist to slide second stage mast (12) over first
stage mast (1). Block second stage mast (12) us-
z Place control cables inside first stage mast (1) tube ing a hardwood block.
to protect them while removing second stage mast
(12). Risk of trapping and severing
Danger!
limbs!
z Hoist second stage mast (12) off of top of first
stage mast(1).
z Remove guides (2, 3, 4) from top of first stage mast
(1).
a hoist.
03 Rev. 3/01
172
MAST MAINTENANCE
z Install two front guides and left side guide ( 7) at z When checking do not use the number that is par-
bottom of second stage mast (12). Do not over tially covered, use the next highest number. Exam-
tighten screws in any of the guides. ple: If the number 7 is partially covered, as shown
in gage reading (34) in Illustration MS-2450-047,
z Use shim gage 125535 (31) to individually check then use number 8 as the guide. Next refer to the
spacing at lower rear and right side between sec- shim chart to find correct combination of shims re-
ond stage mast (12) and first stage mast (1). quired.

MS-2450-047
31 Shim Gage 125535 34 Gage Reading

32 Shim Gage 125539 35 Bottom Shim
33 Mast 36 Top Shim
03 Rev. 3/01
173
MAST MAINTENANCE
z Refer to Illustration MS-2450-046. After determin- z Remove hardwood block and lower second stage
ing the correct amount of shims required (9) install mast (12). Position control cables to front of mast.
them and guides (8) at the bottom right and rear on
– Install two gold shims (5) at top left side of first
the second stage mast (12).
stage mast (1) and second stage mast (12).
They will go between the guides (3, 4) and the
first stage mast (1) with tabs facing in. If two
Shim parts Shim Color Thickness
gold shims (5) will not go into place easily, use
number type
one black and one gold shim (5), if that does
mm inch not fit then go on up the shim list until proper
shim (5) fit is found.
120284-001 Bottom Black 0.381 0.015
– Insert shim gage 125535 (31) into top right side
120284-002 Bottom Gold 0.635 0.025 between first stage mast (1) and second stage
mast (12), select shims from chart and install
120284-003 Bottom Silver 0.889 0.035
as required to guides (2, 4) on top right side of
120283-001 Top Black 0.381 0.015 first stage mast (1).
120283-002 Top Gold 0.635 0.025 – Insert shim gage 125535 (31) into top rear be-
tween first stage mast (1) and second stage
120283-003 Top Silver 0.889 0.035
mast (12). Select shims from chart and install
as required to guides (4) at rear.
Gage Shims Thickness Do not put any shims on guide (2, 3) at front.
reading required
Color z Use hoist to position and put cylinder and yoke (30)
mm inch assembly back into mast.
1 No shims 0.0 0.0 z Bolt yoke to second stage mast (12) and put chain
2 1 black 0.381 0.015 and control cables over proper pulleys on
yoke (30). Chain will go to front of mast and control
3 1 black 0.381 0.015 cables to the rear of the mast.
4 2 black 0.762 0.030
z Install top guides (11, 13) on second stage mast
5 1 silver 0.889 0.035 (12) top.
6 3 black 1.143 0.045
z Using a hoist, slide third stage mast (21) over sec-
7 2 black + 1 gold 1.397 0.055 ond stage mast (12) making sure that control ca-
8 2 gold + 1 black 1.651 0.065 bles do not get pinched during assembly.
9 2 silver 1.778 0.070

10 2 black + 2 gold 2.032 0.080
11 3 gold + 1 black 2.286 0.090
03 Rev. 3/01
174
MAST MAINTENANCE
z Block platform up using a hardwood block. z Use thicker shim gage 125539 (32) and check be-
tween top rear second stage mast (12) and third
z Install guides (14, 15) on lower rear of third stage stage mast (21), select shims and install.
mast (21) after positioning control cables in them.
z Connect batteries, using remote located at front of
z Attach chain anchor (25) to third stage mast (21). vehicle, raise and lower mast one complete cycle.
With mast completely lowered check oil in hydrau-
z Install left side guide (17) on third stage mast (21). lic reservoir, fill as required. Raise and lower mast
thru five or more cycles, and then raise mast com-
z Use shim gage 125539 (32) to check bottom front pletely.
and shim gage 125535 (31) to check bottom right,
to determine shims required between second z At top front of the first stage mast (1) there is a slot-
stage mast (12) and third stage mast (21). ted hole and a slot in the second stage mast (12).
The bleed screw on the lift cylinder is directly be-
z After determining correct number of shims re- hind those slots. Using a screwdriver loosen the
quired, install shims (9) and guides (18) at front bleed screw about one half turn. When hydraulic oil
and shims (9) and guide (16) at right side of third starts to seep out, tighten the bleed screw.
stage mast (21).
z Apply grease (063002-024) to sides of mast in path
z Push cables up into third stage mast (21) until only of guides.
about 255 mm (10 in) of cable is hanging out bot-
tom of mast. z Lower mast completely and check hydraulic oil
level in reservoir, fittings and connections for leaks.
z Feed cables through holes on either side of third
stage mast (21) and platform bottom making sure z Make sure platform height is adjusted properly.
they are seated in guides.
z Control cables will need to be tensioned. See Con-
z Remove hardwood block and lower third stage trol Cables Maintenance in section "Electrical
mast (21) mast completely making sure cables do maintenance, M4“ for procedure.
not get pinched or cut. Remove straps from plat-
form. z Replace load deck and mast cap (22).
z Plug cables into mating connectors located on right z Run operational check.
and left side of platform bottom.
z Secure control cables with cable clamps (27) also Warning! Risk of property damage!
located on right and left hand side of third stage
mast (21).
tional check.
z Replace floorboard and plug in connector for
DMSR and DMSL switches located beneath lower
rear part of floorboard chassis.
03 Rev. 3/01
175
MAST MAINTENANCE
Mast Reshimming z Lower platform (A), chock wheels and disconnect

battery.
(Without removing mast assembly from vehicle)
A procedure for reshimming the mast on WAV50 series

vehicles can reduce down time and labor as most of
the reshimming can be performed at the mast top.
Tools required are common hand tools and approxi-

mately 1 h to perform the procedure.
Top Shims and Guides
Parts needed to complete this procedure are:
Part No. Description Qty

MS-2450-048
120283-001 0.381 mm (0.015 in) Thick 6
(Black) 1 Mast Cap
120283-002 0.635 mm (0.025 in) Thick 4
(Gold) A Part of Platform
120283-003 0.889 mm (0.035 in) Thick 2

(Silver)
z Remove mast cap (1).
z Inspect "land" area (L) on wear guides.
MS-2450-049
L “Land“ Area
When new, the "land" area (L) width is 1.3 mm

(0.050 in). If "land" area (L) is worn into the groove, re-
place the wear guide.
04 Rev. 10/04
176
MAST MAINTENANCE
z Insert prybar (A) between first stage mast and sec-
ond stage mast, see illustration MS-2450-050. This
should move all lateral play to one side of the mast.
z Loosen shim mounting screw (1).
z Insert additional shims (120283-001, 120283-002

or 120283-003) in any combination, into area
shown in Illustration MS-2450-050, additional
shims should slide in by hand and fit snug.
Information
In order to find the correct com-
bination of shims, it may be ne-
cessary to remove existing
shims and start over with a new
combination.
z Once correct shim combination has been found,

remove shim mounting screw (1) and secure addi-
MS-2450-050 tional and/or replacement shims (2).
1 Shim Mounting Screw z Inspect the remaining shims in top of mast using
2 Shim the following illustrations MS-2450-051, MS-2450-
3 “Land“ Wear Indicator
052 and MS-2450-053 as guides.
A Insert Prybar
03 Rev. 3/01
177
MAST MAINTENANCE
z Proceed as described before and replace the worn
shims. C 1
MS-2450-052
B 2 3
1 Shim Mounting Screw
MS-2450-051 2 Shim

C Insert Prybar
2 Shim
B Insert Prybar
03 Rev. 3/01
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MAST MAINTENANCE
Bottom Shims and Guides
D 1
Information
Should additional shimming be
required it may be necessary to
use this same procedure on the
bottom shims and guides.
Shims needed are:
120284-001 0.381 mm (0.015 in) Thick 6

(Black)
120284-002 0.635 mm (0.025 in) Thick 4
(Gold)
120284-003 0.889 mm (0.035 in) Thick 2
2 (Silver)
MS-2450-053

2 Shim
z Lower platform and disconnect battery.

D Insert Prybar
z Verify that all shim mounting screws (1) are se-
cure.
z Connect battery and elevate platform from the
z Refer for lubricating top part of the mast, see sec-
service panel.
tion "Lubrication and Adjustment, M1".
z Platform should raise and lower freely without
z Install mast cap.
binding.
z Connect battery and remove wheel chocks and re-
turn vehicle to operational status.
03 Rev. 3/01
179
MAST MAINTENANCE
MS-2450-054

180
MAST MAINTENANCE
1 First Stage Mast 24 Cable Clamp

2 Guide 40 Third Stage Mast
3 Guide 41 Guide
4 Guide 42 Guide
5 Shim 43 Guide
7 Guide 44 Guide
8 Guide 45 Guide
9 Shim 46 Shim
12 Second Stage Mast 51 Platform Mast
13 Guide 56 Yoke
14 Guide 58 Wire Harness Plug
19 Screw
20 Screw A Strap Placement Platform
21 Chain Anchor B 1.3 mm (0.050 in) Land
22 Mast Cap
Torque Requirements Mast Disassembly
The two 3/8 in diameter screws (19) that secure the Refer to Illustration MS-2450-054.
yoke (56) to the second stage mast (12) must be tight-
ened to 36.5 - 50.5 Nm (27 - 37 ft.lb). z Lower platform completely, turn key switch off, and
disconnect batteries.
The two 3/8 in diameter screws (21), that hold the
chain anchor (20) on the second stage mast (12) must z Attach straps to hoist and platform as shown in A.
be tightened to 36.5 - 50.5 Nm (27-37 ft.lb).
z Unplug connector for DMSR and DMSL switches
located below floorboard. Remove floor board and
mast cap (22).
z Hoist and block platform using a hardwood block.

limbs!
a hoist.
181
MAST MAINTENANCE
z Unplug wire harnesses and remove cable clamps z Remove all shims (5) from top of first stage mast
(24) on either side of platform mast (50) at platform (1) and second stage mast (12).
bottom.
z Remove guides (14, 13) from top of second stage
z Pull wire harnesses and wire harness plugs (58) mast (12). Move wire harnesses to rear of second
through holes in bottom right and left hand side of stage mast (12), unloop chain from pulley and
platform mast (50). place it in the rear of chassis, being careful not to
kink it.
z Remove guides (44, 45) and shims (46) from front
and right side of platform mast (50). z Remove hydraulic line and velocity fuse from base
of lift cylinder being careful to catch any hydraulic
z Remove guides (41, 42, 43) from rear and left side oil that runs out.
of platform mast (50).
z Remove two screws (19) that mount lift cylinder
z Unfasten chain anchor (20) for primary chain from and yoke (56) to second stage mast (12).
third stage mast (40).
z Carefully remove lift cylinder and yoke (56) by lift-
z Remove secondary chain anchors from blocks on ing it out the top of the first stage mast (1).
platform mast (50), detach chain from chain an-
chors. z Use hoist and strap to lift and block second stage
mast (12) using a hardwood block.
z Remove screws and cable track from platform. Pull
cable track part of the way out of bottom of plat- z Remove guides (8) and shims (9) from bottom right
form. and rear of second stage mast (12).
z Hoist platform off of truck being careful not to pinch z Remove guides (7) from bottom front and left side
the control cables and cut them. of second stage mast (12).
z Remove guides from top of third stage mast (40). z Place control cables inside first stage mast tube to
protect them while removing second stage mast
z Remove screws from other end of cable track. (12).
z Remove cable clamps on third stage mast (40). z Hoist second stage mast (12) off of top of first
Remove cable guides from between second stage stage mast (1).
mast (12) and third stage mast (40). Direct cables
so they are straight down from pulleys, between z Remove guides(2, 3, 4) from top of first stage
second stage mast (12) and third stage mast (40). mast (1).
Remove remaining guides from third stage mast
(40). Remove third stage mast (40).
182
MAST MAINTENANCE
Mast Maintenance Mast Assembly
z Clean outside of first stage mast (1), inside and z Install guides (2, 3, 4) back onto first stage mast
outside of second stage mast (12) and third stage (1), do not install any shims at this time.
mast (40) and inside platform mast (50) with a shop
rag to remove dirt and grease. z Place control cables inside first stage mast tube to
protect them from being cut.
z Apply grease (063002-024) to top 150-200 mm
(6–8 in) of the inside four corners of second stage z Use hoist to slide second stage mast (12) over first
mast (12), third stage mast (40) and platform stage stage mast (1). Block second stage mast (12) us-
mast (50). ing a hardwood block.
z Inspect Guides for wear.

limbs!
When new they have a 1.3 mm (0.050 in) land (B) built
in to indicate wear. If the land (B) is worn away to the An unsecured mast and attach-
groove or if the guide surfaces have deep grooves in ments can sever limbs or even
them, the guide has to be replaced. cause fatal injuries. Always
a hoist.
z Install two front guides and left side guide (7) at

bottom of second stage mast (12). Do not over
tighten screws in any of the guides.
z Use shim gage 125535 (31) to individually check

spacing at lower rear and right side between sec-
ond stage mast (12) and first stage mast (1). When
checking do not use the number that is partially
covered, use the next highest number. Example: If
the number 7 is partially covered, as shown in gage
reading (34) in Illustration MS-2450-047, then use
number 8 as the guide. Next refer to the shim chart
to find correct combination of shims required.
183
MAST MAINTENANCE

MS-2450-047
31 Shim Gage 125535 34 Gage Reading

32 Shim gage 125539 or 133403 35 Bottom Shim
33 Mast 36 Top S17him
Shim parts Shim Color Thickness

number type
mm inch
120284-001 Bottom Black 0.381 0.015

120284-002 Bottom Gold 0.635 0.025
120284-003 Bottom Silver 0.889 0.035
120283-001 Top Black 0.381 0.015
120283-002 Top Gold 0.635 0.025
120283-003 Top Silver 0.889 0.035
184
MAST MAINTENANCE
– Insert shim gage 125535 (31) into top right side
between first stage mast (1) and second stage
Gage Shims Thickness mast (12), select shims from chart and install
Reading required as required to guides (2, 4) on top right side of
first stage mast (1).
mm in
– Insert shim gage 125535 (31) into top rear be-
1 No Shims 0.000 0.000 tween first and second stage mast. Select
shims from chart and install as required to
2 1 black 0.381 0.015
guides (4) at rear.
3 1 black 0.381 0.015
4 2 black 0.762 0.030 Do not put any shims on guide (2, 3) at front.
5 1 silver 0.889 0.035 z Use hoist to position and put cylinder and yoke as-
6 3 black 1.143 0.045 sembly back into mast.
7 2 black + 1 1.397 0.055 z Bolt yoke to second stage mast (12) and put chain
gold and control cables over proper pulleys on yoke
8 2 gold + 1 1.651 0.065 (56). Chain will go to front of mast and control ca-
black bles to the rear of the mast.
9 2 silver 1.778 0.070 z Install top guides (13, 14) on second stage mast
10 2 Black + 2 2.032 0.080 (12) top.
Gold
z Using a hoist, slide third stage mast (40) over sec-
11 3 Gold + 1 2.286 0.090 ond stage mast (12) making sure that control ca-
Black bles do not get pinched during assembly.
z Refer to Illustration MS-2450-054. After determin- z Block platform up using a hardwood block.
ing the correct amount of shims (9) required install
them and guides (8) at the bottom right and rear on z Install guides (44, 42) on lower rear of third stage
the second stage mast (12). mast (40) after positioning control cables in them.
z Remove hardwood block and lower second stage z Attach chain anchor (20) to third stage mast (40).
mast (12). Position control cables to front of mast.
– Install two gold shims (5) at top left side of first z Install left side guide (43) on third stage mast (40).
stage mast (1) and second stage mast (12).
They will go between the guides (3, 4) and the z Use shim gage 125539 (32) to check bottom front
first stage mast (1) with tabs facing in. If two and shim gage 125535 (31) to check bottom right,
gold shims (5) will not go into place easily, use to determine shims required between second
one black and one gold shim (5), if that does stage mast (12) and third stage mast (40).
not fit then go on up the shim list until proper
shim fit is found.
185
MAST MAINTENANCE
z After determining correct number of shims re- z Insert two shim gages 133403 (32), one on each
quired, install shims (9) and guides (45) at front side, between third stage mast (40) and platform
and shims (9) and guide (44) at right side of third mast (50) tubes. Adjust the heights of each gage
stage mast (40). so that the lowest visible number on each gage is
the same on each side within one increment of
z Push cables up into third stage mast (40), pull tight each other. Select the appropriate shims from the
and secure with cable clamp (24). shim chart.
z Mount the two slides to the chain sheave pulley as- z For installation of top guides and shims connect
sembly. battery and raise the mast until countersunk holes
are visible and accessible from inside mast tubes.
z Install platform mast (50) over third stage mast
tube prior to installation of any slides. Lower plat- z Install guides and shims at top left and right sides.
form mast (50) down approximately 2/3 the length The screws will install from inside third stage mast
of the third stage mast (40). (40) tube.
z Using shim gage 133403 (32), insert one gage into z Use shim gage 125535 (31) and insert it between
each side of bottom position between the platform third stage mast (40) and platform mast (50) tubes
mast (50) and third stage mast (40) tube. Adjust and in rear position. Using the lowest visible
the heights of each gage so that the lowest visible number, select the appropriate shims from shim
number on each gage is the same on each side or chart. Install mast guides and shims.
within 1 increment of each other. Select the appro-
priate shims from the shim chart. Install mast z Feed cables through holes on either side of third
guides and shims. stage mast (40) and platform bottom making sure
they are seated in guides.
Information z Remove hardwood block and lower mast com-
The cable tracking on the third pletely making sure cables do not get pinched or
stage must be installed prior to cut. Remove straps from platform.
the installation of these guides.
z Plug cables into mating connectors located on right
z Install front guides at the bottom of platform. There and left side of platform bottom.
will be no shims installed.
z Secure control cables with cable clamps (24) also
z Use shim gage 125535 (31) and insert it between located on right and left hand side of mast.
third stage mast (40) and platform mast (50) tubes
at the bottom rear of truck tube. Using the lowest z Replace floorboard and plug in connector for
visible number, select the appropriate shims from DMSR and DMSL switches located beneath lower
shim chart. Install mast guides and shims at this rear part of floorboard chassis.
location.
z Use top shim gage 125539 (32), thicker gage, and
z Lower platform down until the lift chains support it. check between top rear second stage mast (12)
and third stage mast (40), select shims and install.
186
MAST MAINTENANCE
z Connect batteries, using remote located at front of z Make sure platform height is adjusted properly.
vehicle, raise and lower mast one complete cycle.
With mast completely lowered check oil in hydrau- z Control cables will need to be tensioned, see Con-
lic reservoir, fill as required. Raise and lower mast trol Cables Maintenance section of this manual for
thru five or more cycles, and then raise mast com- procedure,see section "Electrical Maintenance,
pletely. M4.
z At top front of the first stage mast (1) there is a slot- z Replace load deck and mast cap (22).
ted hole and a slot in the second stage mast (12).
The bleed screw on the lift cylinder is directly be- z Run operational check.
hind those slots. Using a screwdriver loosen the
bleed screw about one half turn. When hydraulic oil
starts to seep out, tighten the bleed screw. Warning! Risk of property damage!

z Apply grease (063002-024) to sides of mast in path
of guides.
tional check.
z Lower mast completely and check hydraulic oil
level in reservoir, fittings and connections for leaks.
187
MAST MAINTENANCE
Mast Reshimming z Lower platform, chock wheels and disconnect bat-
(Without Removing Mast Assembly From Vehicle) tery.
A procedure for reshimming the mast on WAV50 series

vehicles can reduce down time and labor as most of
the reshimming can be performed at the mast top.
Tools required are common hand tools and approxi-

mately 1 h to perform the procedure.
Top Shims and Guides
Parts needed to complete this procedure are:

MS-2450-048
120283-001 0.381 mm (0.015 in) Thick 6
(Black)
1 Mast Cap
120283-002 0.635 mm (0.025 in) Thick 4
(Gold) A Part of Platform
120283-003 0.889 mm (0.035 in) Thick 2
(Silver)
z Remove mast cap (1).
z Inspect "land" area (L) on wear guides.
MS-2450-049
L “Land“ Area
When new, the "land" area (L) width is 1.3 mm

(0.050 in). If "land" area (L) is worn into the groove, re-
place the wear guide.
188
MAST MAINTENANCE
z Insert prybar (A) between second stage and third
stage, see illustration MS-2450-056. This should
A 2 1 move all lateral play to one side of the mast.
z Loosen shim mounting screw (1). Refer to Illustra-

tion MS-2450-056.
z Insert additional shims (120283-001, 120283-002

or 120283-003) in any combination, into area
shown in Illustration MS-2450-056, additional
shims should slide in by hand and fit snug.
Information
In order to find the correct com-
bination of shims, it may be ne-
3 cessary to remove existing
MS-2450-056 shims and start over with a new
combination.
2 Shim z Once correct shim combination has been found,
remove shim mounting screw (1) and secure addi-
tional and/or replacement shims (2).
A Insert Prybar z Using Illustrations MS-2450-057, MS-2450-058

and MS-2450-059 as guides, repeat steps for re-
maining shims in top of mast.
189
MAST MAINTENANCE
z Proceed as described before and replace the worn
shims (2).
C 2 1
MS-2450-058
2 B 2 3
MS-2450-057 1 Shim Mounting Screw

2 Shim
2 Shim C Insert Prybar
B Insert Prybar
190
MAST MAINTENANCE
Bottom Shims and Guides
1
Information
Should additional shimming be
required it may be necessary to
use this same procedure on the
bottom shims and guides.
Shims needed are:
120284-001 0.381 mm (0.015 in) Thick 6

2 D 2 (Black)
120284-002 0.635 mm (0.025 in) Thick 4
MS-2450-059
(Gold)
1 Shim Mounting Screw 120284-003 0.889 mm (0.035 in) Thick 2
2 Shim (Silver)
z Lower platform and disconnect battery.

D Insert Prybar
z Verify that all shim mounting screws (1) are se-

z Connect battery and elevate platform from the cure.
service panel.
z Refer for lubricating top part of the mast, see sec-
z Platform should raise and lower freely without tion "Lubrication and Adjustment", M1.
binding.
z Install mast cap.
z Connect battery and remove wheel chocks and re-

turn vehicle to operational status.
191
MAST MAINTENANCE
Lift Chain
Lift Chain
The lift chain is a very important component. Safe, un-
interrupted use of the vehicle depends on proper care
and maintenance of the lift chains. Precision chains re-
quire periodic maintenance to deliver maximum serv-
ice life.
Inspection
After every 100 h of vehicle operation, lift chains should

be inspected and lubricated. When used in an ex-
tremely corrosive environment, inspect chains after
every 50 h of operation. During inspection, check for
the following:
Wear
As the chain flexes over the pulleys, the joints gradually

wear.
The "stretch" a chain develops in service is due to ma-

terial being worn off pins outside diameter and pitch
hole inside diameter on the inside plates. MS-2450-060
When checking chain wear, extend the mast com- 1 New Chain
pletely and check the section of chain that operates
2 Streched Chain
over the pulley, this section of chain should show the
3 Wear Scale 106440
most wear. Chain wear can be measured using a wear
scale 106440 (3), see illustration MS-2450-060, or a
steel tape. When a chain has elongated 3%, it should
If wear scale 106440 (3) is used to check chain wear,
be replaced. The chain used has a 12,7 mm (0.50 in)
place one "A" scale tip in center of a chain pin, then
pitch.
look at the center of the second "A" scale tip. If the
center of the 24th chain pin down is even with the
center of that tip, the chain should be replaced.
If a scale is used to check chain wear, place the end of

the scale in center of a chain pin. Count down 24 pins
and if the center of that pin has stretched to 314 mm
(12.375 in) the chain should be replaced. With a new
chain, you would read 305 mm (12 in).
Do not repair chains by cutting out the worn section

and splicing in a new piece. If part of a chain is worn,
replace both of the lift chains.
03 Rev. 8/04
192
MAST MAINTENANCE
Lift Chain
Rust and Corrosion Corroded chains should be inspected for cracked
plates. Outside plates are particularly susceptible to
Chains are highly stressed precision components. It is stress corrosion cracking. If chains are heavily rusted
very important that original manufactured strength and or corroded they should be removed from mast for thor-
fatigue strength be maintained throughout the chain ough inspection for cracked plates. If plates are
service life. cracked, replace both chains. Oil chains when installed
on the mast.
Cracked Plates
The most common cause of plate cracking is fatigue

failure. Fatigue is a phenomenon that affects most met-
als and many plastics. After many repeated heavy
MS-2450-061
loads the chain plates may crack and chains will even-
tually break.
Corroded chain with stress/corrosion cracks
Corrosion will cause a major reduction in the load car-

rying capacity of lift chain or roller chain because cor-
rosion causes side plate cracking. It is very important
to protect lift chains from corrosion, in service or in stor-
age. The original lubricant applied by the factory to
chains is an excellent rust and corrosion inhibitor. Fac-
MS-2450-062
tory lube is applied in a hot dip tank to insure complete
penetration into joints. Do not steam clean or degrease
Fatigue cracks
new chains. After chain has been placed into service,
factory lube must be supplemented by a maintenance
lubrication program. Fatigue cracks are almost always found through the
pitch holes perpendicular to the pitch line as shown in
Refer to the lubrication and adjustment section of this Illustration above. Contrast this failure to the random
manual and/or the lubrication information contained failures caused by stress/corrosion cracking as shown
later in this section. in Illustration MS-2450-061. If any fatigue cracks are
discovered at any time replace both chains. If cracks
Chain and steel cable fluid serves as a joint lubricant are found in one or more chain plates then many more
and corrosion inhibitor. During inspection, carefully ex- plates that appear sound may have small cracks mak-
amine external chain surfaces for presence of an oily ing chain failure very likely.
film. Under certain operating or environmental condi-
tions it may be necessary to oil chains more than 100 h
intervals. In all cases, external surface of chain must be
protected with a film of oil.
03 Rev. 8/04
193
MAST MAINTENANCE
Lift Chain
Tight Joints If chain is allowed to operate in this condition, the pins
slowly work out of the chain, causing chain failure.
All joints in the chain should flex freely. Tight joints re- Turned pins can be quickly spotted because the flats
sist flexing, increasing internal friction, thus increasing on the "V" heads are no longer in line. Refer to Illustra-
wear and fatigue problems. tion MS-2450-064, pin has been turned 45°. Chain with
turned or protruding pins should be replaced immedi-
ately.
Never attempt to repair a chain by driving pins back

into the chain.
Chain Side Wear

MS-2450-063
Continuous wear on pin heads and outside plates indi-
Tight joints cates misalignment. Misalignment can be caused by
two different factors: unequal chain tension or mis-
alignment between pulleys and chain anchors.
Tight joints in lift chain can be caused by:
– Bent pins or plates
Unequal Chain Tension
– Rusty/corroded joints
– Peened plate edges z When a lift chain is installed or adjusted, care
should be taken to "load" the chains evenly. When
Oil rusty chains and replace chains that appear bent or adjusting platform height make sure the chain ten-
peened. Peening of chain plate edges may be caused sion is equal.
by worn pulleys, unusually heavy loads, or chain sliding
past a guide or obstruction in the mast. z After the platform height is set raise it at least half
way up and check chain tension by pressing on
each chain with a finger. Adjust the chain anchor
Protruding or Turned Pins on the loose chain until the tension feels equal. Se-
cure the chain anchor position with the nuts on its
Heavily loaded chains operating with little lubrication back side.
generate tremendous friction between pin plates (pin
and bushing in roller chains). In extreme cases, fric- Non Alignment of Lift Components
tional torque in the joint can turn pins in the outside
plates.
Non Alignment of the chain with the pulley due to incor-
rect shimming of mast, bent or damaged mast or cylin-
der components can also contribute to chain side wear.
MS-2450-064
Protuding and turned pin
03 Rev. 8/04
194
MAST MAINTENANCE
Lift Chain
Lift Chain Lubrication The multi plate construction of leaf chain provides more
paths for the lubrication to reach the pin. Wipe the
chain clean, do not steam clean or degrease, and apply
Lubrication is a very important factor in lift chain field lubrication to chain.
maintenance. Lift chains should be lubricated on a
planned maintenance schedule. Like all bearing sur-
faces, the precision manufactured, hardened steel, Lift Chain Replacement
wear surfaces require a film of oil between mating parts
to prevent rapid wear.
An important factor in ordering replacement chain from
Maintaining an oil film on all chain surfaces will: the vehicle manufacturer is the special chain used in
this vehicle has a certified minimum ultimate strength.
1. Minimize joint wear (chain stretch).
Replace both chains as a pair. It is almost impossible
to maintain uniform loading between the chains if one
2. Prevent corrosion.
is old and one is new. The joints in the old chain may
have worn through the hardest layer of the case hard-
3. Reduce the possibility of pin turning. ened pin. Therefore the wear rate on the old chain will
be greater than that on the new chain, greatly compli-
4. Minimize tight joints in roller chain. cating the problem of maintaining equal chain tension.
The new chain will not wear as quickly, causing it to
bear the major portion of the load, resulting in prema-
5. Promote smooth, quiet chain movement.
ture wear and fatigue failure.
6. Lower chain tension by reducing friction in the

chain. Lift Chain Removal
Chain and steel cable fluid is the recommended lubri- 2135 mm (84 in) Lift Height:
cation to be used on lift chain. Frequency of chain lubri-
cation will vary with operating conditions and environ- z Raise and block platform using a hardwood block.
ment. The chain should be lubricated every 100 h of
vehicle operating time. Vehicles used outdoors or in 2995 mm (118 in) Lift Height:
severe service may require lubrication after every 50 h
of vehicle use. z Raise and block third stage mast using a hardwood
block.
In dusty operating conditions, lubed chains will gather
dust. Even under these conditions wear lift will be z Turn key switch off, disconnect batteries, remove
greatly improved by periodic lubrication. Joints may ac- mast cap, unplug connector for DMSR and DMSL
quire a "paste" made up of oil and dirt, but joint wear switches located below rear part of floorboard
will still be much less than if the chain is allowed to run chassis, and remove floorboard.
dry with metal to metal contact between pins and
plates. z Remove access covers and "H" frame (3 pieces)
from rear of vehicle.
03 Rev. 8/04
195
MAST MAINTENANCE
Lift Chain
MS-2450-066
03 Rev. 8/04
196
MAST MAINTENANCE
Lift Chain
8 Nut 18 Chain Anchor

12 Chain Anchors 19 Hardware
22 8 mm (0.3125 in) Shim Location
13 Chain Pin 23 Third Stage Mast
14 Cotter Pin 24 Old Chain
16 Retaining Ring 25 Wire
17 Pin 26 New Chain
z Loosen chain anchors (12) so that the chain has a z Turn key switch off and adjust chain anchors
little slack in it. evenly until platform is just rising off of 8 mm
(0.3125 in) shim plates. The dimension to the back
z Remove cotter pin (14) and chain pin (13). edge of the platform should be approximately as
shown in Illustration below.
z Remove hardware (19) holding chain anchor (18)
to third stage mast (23) and pull anchor and chains
down below third stage mast about 150 mm
(6.0 in). Use wood wedge between third stage
mast (23) and chain so that chain is not pulled back
up into mast.
z Remove one retaining ring (16), pin (17) and chain

anchor (18) from old chain (24).
z Wire (25) end of new chains (26) to old chains (24)

as shown in A. Mount chain anchor (18) to new
chain (26). Use new pin (17) and retaining rings +
(16).
z Remove wood wedge and pull chain through rear MS-2450-065

bottom (platform side) of third stage mast.
H 270 mm (10.56 in) for 2135 mm (84 in) Lift Height
z Secure chain anchor (18) to third stage mast (23)
with mounting hardware (19).
z After chains are tensioned, raise mast at least half
z Remove wire (25) holding new chain (26) and old way up and check chain tension by pressing on
chain (24) together. each chain with a finger. Adjust the chain anchor
on the loose chain until the tension feels equal. Se-
z Mount chain to chain anchor (12). Use new chain cure the chain anchor (12) position with the nuts (8)
pin (13) and cotter pin (14). on its back side, see illustration MS-2450-066. Re-
move temporary shim plates.
z Adjust chain anchors to remove slack from chains.
z Replace "H" frame, access covers, floorboard and
z Place two temporary 8 mm (0.3125 in) shims (22) mast cap. Plug in connector for DMSR and DMSL
on top of tube of the chassis traverse nearby the at lower rear of platform.
mast. This will automatically set platform height and
allow cushioning of cylinder to operate properly. z Run operational check.
z Connect batteries, remove hardwood block and

lower platform completely on 8 mm (0.3125 in)
shims using chassis console.
03 Rev. 8/04
197
MAST MAINTENANCE
Lift Chain
Secondary Chain Replacement
2995 mm (118 in) Lift Height Only
MS-2450-067
03 Rev. 8/04
198
MAST MAINTENANCE
Lift Chain
36 Chain 49 Part of First Stage Mast

37 Mounting Pin 50 Part of SecondStage Mast
38 Cotter Pin 51 Part of ThirdStage Mast
47 Chain Anchor 52 Lifting Tool
z Raise platform from service panel until cable track z Remove cotter pin (38) and mounting pin (37) from
mounting to third stage mast (51) is visible. Block second stage mast (50) for each chain (36).
mast and remove track from third stage mast (51).
Pull track down slightly so that the studs are below z Attach one end of new chain (36) to the second
mounting plate. stage mast (50) using mounting pin (37) and cotter
pin (38) from former step.
z Remove blocks and lower platform to a height of
approximately 915 mm (36 in) above the ground z Attach other end of chain (36) to existing chain (36)
(measured to the top of rear skirt) and re-block the with a wire. Pull on object at the end of wire or
mast. Turn key switch off and disconnect batteries. spare chain until new chain (36) is taunt.
Disconnect CA101, CA102 and cable clamps on
platform. Drop cable down through holes in plat- z Lower third stage mast (51), making sure new
form. Remove cable track from platform. chain (36) feeds over pulleys until third stage mast
(51) comes to rest when primary chain (36) is fully
z Remove chain (36) from platform chain anchors tensioned.
(47).
z Install cable guides and pull cables tight over studs
z Remove guides and shims from lower left and right and clamp to third stage mast (51), maintaining
side of platform. Remove cable clamp from left and tension. For control cable installation and tension-
right side of third stage mast (51). Pull cable and ing, see section "Electrical maintenance", M4.
track down from in between platform and third
stage mast (51) . Lift platform off of third stage z Install corner guides at top of third stage mast (51)
mast (51) using straps and a crane. and place platform back on vehicle.
z Remove guides and shims between third stage z Feed cable track back up in between third stage
mast (51) and second stage mast (50), top and bot- mast (51) and platform mast. Attach cable track to
tom, including “J” shaped groove cable guides. platform, connect CA101 and CA102. Pull any
slack in dynamic cable into platform and install ca-
z Attach another equal length section of chain or ble clamps to platform.
wire with an object on the end to each chain (36)
with a wire. z Install shims at lower left and right of platform. Re-
fer to section M7.0 for proper mast alignment.
z Attach third stage mast lifting tool (52) or similar
across top of the third stage mast (51). Lift third z Connect batteries and raise platform from service
stage mast (51) with a crane and hook attached to panel. Block platform and attach cable track to
lifting tool (52) until secondary chain mounting on third stage mast mounting plate.
second stage mast (50) is visible.
z Remove blocks, install removed covers and run
operational check.
03 Rev. 8/04
199
MAST MAINTENANCE
Lift Chain
Leaf Chain Disconnect
MS-2450-068
1 Pin Link Plate 4 Pin

2 Work Surface Knock Out Aperature 5 Grinding Wheel
3 Support Ring
To minimize the risk of damaging (cracking, etc.) the

chain, refer to the following when disconnecting leaf
chain. Warning! Risk of injury!
Grinding produces fragments

Equipment Required: which can cause severe eye in-
jury. Do wear protective
1. A sturdy surface with an opening slightly greater glasses!
than the pin diameter, and should be thick enough
to allow the pin to extend beneath the work surface Disconnect Procedures:
as it is driven through the bottom pin link plate (1).
z Grind the top head of the pin (4) flush with the pin
2. A support ring (3) with an inside diameter slightly link plate (1). Be careful not to grind or damage the
greater than the pin diameter and a height equal to pin link plate (1).
the head height of the pin.
z Position the support ring (3) over opening of the
work surface knock out aperature (2). The support
3. Grinding wheel (5).
ring (3) serves to support the bottom pin link plate
(1) and avoids damage to chain components while
4. Pin punch with a diameter slightly less than the pin driving the pin (4) through the chain.
diameter.
z Stand the chain on its side and seat pin (4) in the
5. Hammer or arbor press. supporting ring (3).
z Remove the pin (4) through the top pin link

plate (1).
03 Rev. 8/04
200
CYLINDER MAINTENANCE
Printed in Germany
201
Notice:
Printed in Germany
202
General
General General Instructions for Repairing Hydraulic Com-

ponents
Warning! Risk of serious injury from Great care and cleanliness should be exercised in the
pressurized hydraulic oil! disassembly and assembly of any hydraulic cylinder
Pressurized hydraulic oil can (11).
penetrate the skin. This is a se-
rious medical emergency which z Wipe all surfaces clean of dirt and oil before at-
requires immediate medical attempting disassembly.
tention.
The skin will not show any obvi- z Care should be taken when removing the ram as
ous initial damage and the nicks will damage the packings.
physical effects will not be man-
ifested immediately. Seek medi- z After the hydraulic cylinder (11) components are
cal assistance if your skin has disassembled and hydraulic seals, O-rings and
been affected by pressurized wipers are removed, thoroughly wash all metallic
hydraulic oil. parts in solvent and blow dry with compressed air.
For your personal protection:
Depressurise the hydraulic sys- z Carefully inspect the ram assembly and cylinder
tem before starting assembly bore. Replace if scored, grooved, pitted or worn.
work on the hydraulic system. Minor damage to the cylinder bore can be removed
After carrying out assembly with the use of a hydraulic cylinder honing tool.
work carefully check to see that
all ports are tightened before re- z Place washed components in a clean container un-
pressurising the system. til reassembly.
Wear protective clothing, safety
glasses and safety gloves when z Whenever new packings are required, new wiper
tracing leaks or bleeding the rings should also be installed.
system.
Use a piece of absorbent paper
to trace leaks, never use your
hands.
Follow the hydraulic oil manu-
facturer’s safety instructions
when handling these oils.
203
Cylinder Removal
Cylinder Removal
MS-2450-069
04 Rev. 8/04
204
Cylinder Removal
1 Screw 12 Hardwood block

2 Chain Anchor 13 Hardwood block
3 Retaining Ring 14 Manual Lowering Valve
4 Pin 15 Inspection Plate
5 Chain 16 Part of Third Stage Mast
6 Yoke 19 Bridge Weldment
7 Cable Clamp 20 Hose
8 Screw
9 Screw M3 Pump Motor
10 Mast Cap Cover P1 Contactor Pump Motor
11 Hydraulic Cylinder SV1 Solenoid Valve
z Remove mast cap cover (10). z Remove four screws and access cover on lower
front of third stage mast (16) to expose lift chains
z Remove bridge weldment (19) from second stage (5).
mast (2995 mm [118 in] only).
z Remove inspection plate (15).
z Refer to Illustration MS-2450-069. Raise platform
and block, using two, 100 x 100 mm (4 x 4 in) equal z Remove two screws (1) holding chain anchor (2)
length hardwood blocks (12) approximately 180 to from lower third stage mast (16).
205 mm (7 to 8 in) long.
z Pull lift chain (5) down through third stage mast
z Turn key switch to "OFF", remove load deck and (16) to expose chain anchor (2) completely.
disconnect batteries.
z Remove retaining ring (3) from one side of chain
z Release hydraulic pressure from system with man- anchor (2) assembly. Slide pin (4) out and remove
ual lowering valve (14) located on the end of sole- chain anchor (2), being careful not to let chains (5)
noid valve (SV1). pull up through mast.
z Unplug connector for DMSR and DMSL switches z Using a piece of wire 1220 mm (48 in) long, tie
located below floorboard. Remove floorboard and ends of chain (5) together and slowly feed back up
set aside. through third stage mast (16).
z Place a mark on cable even with the backside of z Pull chains out top of mast and lay them over to the
each cable clamp (7) using a marker or piece of rear.
tape.
z Remove cable clamps (7).

Information
Inspect lift chains using Crown
z Unplug connectors CA101 and CA102. wear scale 106440 per instruc-
tions in section "Mast mainte-
z Pull cables down through floorboard beside third
nance", M7.
stage mast (16).
04 Rev. 8/04
205
Cylinder Removal
z Place shop rags below velocity fuse at bottom of lift Disassembly
hydraulic cylinder (11) and remove hydraulic line
from velocity fuse. Remove the yoke assembly by driving out the roll pin.
To disassemble the hydraulic cylinder (4), use a span-
z Remove velocity fuse making sure to clean up any ner wrench (1) and turn the cap (2) counterclockwise to
oil that may run out of hydraulic cylinder (11) or hy- unscrew it from the hydraulic cylinder tube. Carefully
draulic line. extract the ram (3) assembly from the cylinder bore, do
not allow ram (3) to contact any sharp edges.
z Pull slack in control cables up through top of mast
and remove cables from yoke (6). Be careful not to
pull control cable plugs up into mast.
z Remove two screws (9) holding yoke (6) assembly

to second stage mast.
z Note orientation of yoke (6) in mast. Pull up on

yoke (6) until cylinder ram is fully extended. Con-
tinue to lift hydraulic cylinder (11) from mast rotat-
ing as required for removal. Be careful not to let
ram drop back down into cylinder while removing
from mast, doing so will result in a larger oil spill.
z Remove yoke (6) from hydraulic cylinder (11) and

perform hydraulic cylinder (11) maintenance.
MS-2450-070
1 Spanner Wrench
2 Cap
3 Ram
4 Hydraulic Cylinder
03 Rev. 3/01
206
Cylinder Removal
Hydraulic Seals Thoroughly clean the area where the seal seats. Any
burrs, dirt or seal debris must be removed before in-
stalling new seals.
The hydraulic seals used in the hydraulic cylinder are
made from an extremely durable, hard polyurethane
material which can be deformed temporarily to allow for Caution! Risk of property damage!
installation without permanent damage.
Close inspection of hydraulic
When an excessive amount of hydraulic oil is evident seal seating critical areas
around the area where the ram exits from the cap, the should be made before the new
hydraulic seal is probably damaged and should be re- hydraulic seal is installed. Your
placed. seal failure may not have been
caused by a worn hydraulic
The hydraulic cylinder (4) must be removed from the seal, but rather, by burrs, nicks
truck to perform hydraulic seal replacement. and dirt located on the hydraulic
seal seating area, causing the
z Unfasten and remove the cap as explained before hydraulic seal to deform and
in "Disassembly". lose its sealing ability.
Caution! Risk of damage and leakage! Hydraulic Seal Installation

Never use a screwdriver to re- Tools used to install hydraulic seals should be of soft
move hydraulic seals, as dam- metal or suitable plastic, free of burrs and sharp edges.
age and leakage may result. Screwdrivers and other similar tools should not be
Tool should be constructed of used as they may damage the sealing edges.
aluminium or brass so as not to
scratch or nick any surfaces. The area in contact with the hydraulic seal should be
free of burrs, sharp edges and nicks. If necessary to
The hydraulic seal is seated inside the cap so a hooked force hydraulic seal over sharp edges, slots or under-
tool should be used to remove the hydraulic seal (see cuts, protective devices should be used. Light lubrica-
illustration below). At this time the rod wiper ring should tion should be applied to the hydraulic seal and instal-
also be removed since the hydraulic seal and the wiper lation groove prior to installation. The same oil as will
should always be replaced in pairs. be used later in the cylinder should be applied.
MS-2450-071
A 130 mm (5 in)
03 Rev. 3/01
207
Cylinder Removal
Installation Procedure
3 4 z Slip hydraulic seal (5) over the fixed pin (1) and
bend it over pin (2) as shown.
z Continue bending hydraulic seal (5) until pin (3)

can be pushed through the hydraulic seal (5) loop
1 which locks hydraulic seal (5) in position.
2
2
3 4
3
5
MS-2450-072
2 1
1 Pin
2 Pin 2
6
3 Pin
4 Installation Tool
5 Hydraulic Seal MS-2450-073
1 Pin
Installation Tool 2 Pin
3 Pin
An installation tool (4) made of any soft metal or hard 4 Installation Tool
plastic machined smooth and free of burrs with a fixed
6 Cylinder Bore
steel pin (1) and two movable pins (2, 3) is required for
this installation method. See Illustration above.
z Insert installation tool (4) with mounted hydraulic
seal (5) into cylinder bore (6) until aligned with hy-
draulic seal (5) installation groove.
03 Rev. 3/01
208
Cylinder Removal
3 3
1 1
2
2
MS-2450-074
MS-2450-075
1 Pin
1 Pin
2 Pin
2 Pin
3 Pin
3 Pin
4 Installation Tool
z Withdraw pin (3) so that hydraulic seal (5) loop
snaps into installation groove.
z Withdraw pin (2) and hydraulic seal (5) will com-
pletely snap into installation groove see Illustration
above.
z Withdraw installation tool (4).
z After packings and hydraulic seal (5) are in place

and the ram has been installed, reattach the cap.
Care should be taken when in-

serting the cylinder cap to pre-
vent threads and sharp edges
from damaging new seals and
packings.
03 Rev. 3/01
209
Cylinder Replacement
MS-2450-076

1 Screws 6 Cotter Pin
2 Inspection plate 7 Part of Chassis
3 Bolt 8 Cylinder Bleed Screw Access Hole
4 Washer 9 Screw
5 Tension Bracket
04 Rev. 8/04
210
z Replace yoke on cylinder. z Plug cable connectors CA101 and CA102 back
into their mating connectors on the right and left
z Tighten cable tension bolt (3) until tension bracket sides of the platform.
(5) touches chassis (7).
z Feed chains down through mast between second
and third stages and out bottom of platform.
z Connect chain to anchor with pin and clips. Secure
Improper placement of control
chain anchor to third stage mast with two mounting
cables may cause severe dam-
screws.
age.
Be careful not to damage con-
z Loosen cable tension bolt (3) until cotter pin (6)
trol cables during procedure.
bottoms out on tension bracket (5) putting tension
back on control cables.
z Orient cylinder and yoke by turning cylinder until
velocity fuse port is pointing 45° left of the mast
z Install floorboard. Plug connectors for DMSR and
front. Slide cylinder down into mast. After cylinder
DMSL switches into mating connectors below
is installed in mast, rotate cylinder back to align
floorboard.
port with hole in lower mast. Continue to lower ram
and yoke assembly into mast making sure cables
z Connect batteries and using remote service panel
are in proper position on pulleys before yoke slides
raise platform completely, remove hardwood
into third stage mast.
blocks and lower completely.
z Connect yoke assembly to second stage mast with
two 3/8 inch screws (9). Danger! Risk of trapping and severing
limbs!
z Install velocity fuse in bottom of lift cylinder. Torque When removing hardwood
to 27 Nm (20 ft.lb) maximum. blocks, raise platform com-
pletely before lowering to pre-
z Connect hydraulic line to velocity fuse. Torque to vent platform from dropping
27 Nm (20 ft.lb) maximum. quickly.
Do not operate lift or lower cycle
z Pull plug end control cables down and feed back from platform before cycling
up through floorboard. per instructions.
z Secure control cables with cable clamps, ensuring z Check hydraulic fluid level and fill as required.
that marks previously put on cables are in their re-
spective positions. z From remote service panel raise and lower plat-
form completely at least five times. Check for hy-
draulic leaks while cycling. This will force any air
trapped in the system to the top of the cylinder.
04 Rev. 8/04
211
z Raise platform completely, exposing the cylinder z Tighten cylinder bleed screw and wipe off all ex-
bleed screw through the access hole (8) in the cess oil.
mast as shown in Illustration MS-2450-076. Care-
z Install bridge weldment (2995 mm [118 in] only).
fully loosen the small bleed screw, located at the
top of the cylinder, until all air escapes and only oil z Install mast cap, inspection plate, access cover
continues to flow from the screw. (2135 mm [84 in] only) and load deck.
z Drive vehicle and check operation.
04 Rev. 8/04
212
Velocity Fuse Replacement z Connect hydraulic hose (20) to velocity fuse.

Torque to 27 Nm (20 ft.lb) maximum.
z Refer to Illustration MS-2450-069. Raise mast
enough, using service panel, to block second Danger! Risk of trapping and severing
stage mast with two, equal length 100 x 100 mm limbs!
(4 x 4 in) hardwood blocks 180 to 205 mm When removing hardwood
(7 to 8 in) long. Be sure to block second stage blocks, raise platform com-
mast, not platform and clamp blocks in position. pletely before lowering to pre-
vent platform from dropping
z Remove load deck and disconnect batteries. quickly.
Do not operate lift or lower cycle
z Remove inspection plate (15). from platform before cycling
per instructions.
z Release hydraulic pressure in system with manual
lowering valve (14), located on end of solenoid z Connect batteries and using service panel, raise
valve (SV1). platform completely, remove hardwood blocks and
lower platform completely.
z Place shop rags under velocity fuse and hose to
catch any hydraulic oil lost during removal. z Check hydraulic fluid level and fill as required.
z Disconnect hose (20) from velocity fuse. z Raise and lower platform completely at least five
more times. Check for any hydraulic leaks while
z Remove velocity fuse and replace with new veloc- cycling. Refer to "Cylinder Bleeding", page 214 be-
ity fuse as required. Torque to 27 Nm (20 ft.lb) fore proceeding and bleed as described.
maximum.
z Replace inspection plate (15) and load deck.
z Check vehicle operation.
03 Rev. 3/01
213
Cylinder Bleeding Cylinder Summary
After the cylinder is re-installed on the vehicle, but be- Occasionally, a slight creep of the platform assembly
fore the vehicle is put back into operation, air must be may occur. This may be due to internal leakage in the
bled from the hydraulic system. Without a load on the packing but it can also be caused by leakage in the
platform and the elevation control switch (ECS) on the solenoid or check valve. To seat these valves properly
service panel in base position, raise and lower the mast when this occurs, raise and lower the platform to flush
by using the remote Raise/Lower switch on the service out any foreign material from the valve seat.
panel through one complete cycle. With the platform
fully lowered, check the hydraulic reservoir and add A thorough check of the system for leaks should be
fluid if necessary. Raise and lower the platform through conducted if abnormal oil losses occur. The hydraulic
the complete cycle at least five more times. system is designed to eliminate mechanical damage
even if fittings become loose.
This action will force any air that may be trapped in the
system to the top of the cylinder. Then raise platform all
the way, exposing the bleed screw through the access
holes in the masts. Loosen the small bleeding screw,
located at the top of the cylinder until all air escapes
and only oil continues to flow from the screw. Tighten
the screw and wipe off all excess oil. Lower platform
and place elevation control switch in platform position
on service panel.
03 Rev. 3/01
214
PLATFORM MAINTENANCE
Printed in Germany
215
Notice:
Printed in Germany
216
Load Tray
Load Tray

MS-2450-077
A Load Tray in Locked Position

B Load Tray in Un-Locked Position
1 Load Tray 3 Carriage
2 Locking Pin 4 Track
z The load tray (1) is designed to carry a maximum and move it up or down as desired. To lock the load
load of 90 kg (200 lb). tray (1) in position rotate it back to the horizontal
position. Push down at the rear of the tray to insure
z The load tray (1) can be adjusted up or down to that the locking pin (2) is at the bottom of the retain-
four different horizontal positions. ing slot.
z The load tray (1) can be locked in the full vertical z To lock the load tray (1) in the full vertical position,
position for better access to the load deck. rotate it up as far as it will go, lower until it comes
in contact with the spring cushion and then push it
down to compress the spring cushion. Push the
Operation load tray (1) under the lip on top of the track (4) and
allow it to spring back up and lock in position.
z To move the load tray (1) to a different position,
rotate it up approximately 70° to release the lock-
ing pin (2) as shown in Illustration MS-2450-077
01 Rev. 3/01
217
Load Tray
MS-2450-078
1 Track 15 Tray Assembly

2 Nut 16 Ball Bearing and Nylon Spacer
3 Bottom Plate 17 Bumper
4 Screw 20 Compression Spring
8 Carriage 22 Screw
9 Pin 23 Locking Pin
10 Retaining Ring 25 Extension Spring
11 Link 26 Mast
12 Pin 27 Screw
13 Retaining Ring
01 Rev. 3/01
218
Load Tray
Load Tray Disassembly Load Tray Assembly
z Raise platform approximately 610 mm (24 in) and z Raise platform approximately 610 mm (24 in) and
turn key switch to off position. Lock load tray in sec- turn key switch off.
ond position down, allowing access to springs (25).
z Install track (1) on mast (26) using four screws (27)
z Remove flat head screws (4) and then remove bot- and four nuts (2) torqued to 36.5-50.5 Nm (27-
tom plate (3). 37 ft.lb). Do not drop screws down mast.
z Remove extension springs (25) from top of track z Install roller bearings (16) on carriage (8) and se-
(1). cure using nylon spacers.
z Rotate load tray up to release locking pin (23), then z Assemble spring cushion on carriage (8) and se-
remove carriage (8) and tray assembly (15) cure.
through bottom of track (1).
z Mount load tray to carriage (8) using pin (9) and
z Remove extension springs (25) from carriage (8) retaining rings (10).
by unhooking from carriage (8).
z Install links (11) on locking pin (23) using one pin
z Remove locking pin (23) by removing retaining (12) and two retaining rings (13).
rings (13) from pin (12). Then remove pin (12) from
links (11). z Install extension springs (25) on carriage (8).
z Remove load tray from carriage (8) by removing z Install load tray assembly into bottom of track (1).
retaining ring (10) from pin (9) and then remove pin
(9) and load tray. z Connect extension springs (25) to top of track (1).
z Remove spring cushion assembly at bottom of car- z Mount bottom plate (3) to track (1) using two
riage (8) by removing bumper (17) from screw (22). screws (4).
z Remove nylon spacers and ball bearings (16). z Check operation of tray assembly.
z Remove track (1) from mast by removing screws z The ball bearings (16) are pre-lubricated and will
(27) and nuts (2). Be careful not to drop screws not require further lubrication. The outside of the
(27) down mast. bearing, which runs on the track (1), is intended to
run dry without lubrication.
01 Rev. 3/01
219
Notice:
Printed in Germany
220
GLOSSARY
Printed in Germany
221
GLOSSARY
Notice:
Printed in Germany
222
GLOSSARY
Components have been listed in chart form to assist The COMPONENT (first) column contains the abbrevi-
the maintenance mechanic in locating these compo- ation of the component as it appears on the Diagrams
nents on the Electrical Diagrams and Parts Breakdown in the Maintenance Section. The LOCATION column
forms. gives the general location on the truck such as on plat-
form or in chassis. The FUNCTION column then ex-
The chart is in columns: plains the function or circuit of that device. The DIA-
GRAM column gives the page number of the diagram
– COMPONENT,
on which the component can be found.
– LOCATION,
– FUNCTION, Information
The PARTS BREAKDOWN co-
– DIAGRAM,
lumn includes the page number
– PARTS BREAKDOWN. in the parts manual where the
component is located along
with the index number, in paren-
thesis, if applicable.
02 Rev. 10/04
223
GLOSSARY
Audible Indicators
Information
The PARTS BREAKDOWN co-
lumn includes the page number
in the parts manual where the
component is located along
with the index number, in paren-
thesis, if applicable.
Location Function Diagram Parts Breakdown
ALM Contactor Panel Warning Alarm Page 246 Page 34 (03)

Page 247
Page 250
Page 254
Page 255
Page 258
HN Contactor Panel Horn Page 246 Page 34 (04)
Page 247
Page 250
Page 254
Page 255
Page 258
Battery
Battery Chassis Power Page 246 Page 12 (2)

(Maintenance Free)
Page 251
Page 254
Page 259
02 Rev. 10/04
224
GLOSSARY
Connections
CA101 Platform Dynamic Cable Termination Page 248 Page 30 (4)

Page 256
CA102 Platform Dynamic Cable Termination Page 248 Page 30 (4)
Page 256
CA203 Chassis Strobe Trigger Page 249
Page 257
CA204 Chassis Strobe Trigger Page 249
Page 257
CA303 Platform Deadmen Switches Assembly Page 248 Page 30 (4)
Page 256
CA304 Platform Height Switches Assembly Page 248 Page 30 (4)
Page 256
CA305 Platform Strobe Control Page 248 Page 30(4)
Page 256
CA306 Platform Strobe PLSLL Page 248 Page 30 (4)
Page 256
CA307 Platform Strobe PLSLR Page 248 Page 30 (4)
Page 256
CA308 Platform Load Tray Page 256
CA309 Platform Load Tray Page 256
CA401 Chassis (MRC1) System Controller Page 247 Page 30 (1)
Page 249
Page 255
Page 257
CA402 Chassis (MRC1) Communications Port Page 247 Page 30 (4)
Page 249
Page 255
Page 257
CA403 Service Panel Service Panel Page 249 Page 30 (4)
Page 257
02 Rev. 10/04
225
GLOSSARY
CA404 Service Panel Service Panel (AC Connector) Page 249 Page 44
Page 251
Page 257
Page 259
CA405 Service Panel AC Inlet Page 249 Page 44 (13)
Page 257
CA406 Service Panel Strobe CHSLF Page 249 Page 30 (4)
Page 257
CA407 Service Panel Charger LED’s Page 249 Page 30 (4)
Page 251
Page 257
Page 259
CA501 Steering Pod Static Harness Termination Page 248 Page 30 (4)
Page 256
CA502 Traction Pod Static Harness Termination Page 248 Page 30 (4)
Page 256
CA601 Chassis Traction Motor M1 Page 249 Page 30 (2)
Page 257
CA602 Chassis Traction Motor M2 Page 249 Page 30 (2)
Page 257
CA603 Chassis Left Brake (Positive) Page 249
Page 257
CA604 Chassis Left Brake (Negative) Page 249
Page 257
CA605 Chassis Right Brake (Positive) Page 249
Page 257
CA606 Chassis Right Brake (Negative) Page 249
Page 257
CA607 Service Terminal Communications Port Page 247
Page 249
Page 255
Page 257
CA608 Chassis Strobe Control CHSC Page 249 Page 30 (4)
Page 257
02 Rev. 10/04
226
GLOSSARY
CA701 Steering Pod Display Page 247 Page 30 (1)

Page 248
Page 255
Page 256
CA702 Traction Pod Right Sensor Page 248 Page 30 (3)
Page 256
CA703 Steering Pod Key Pad - 2135 mm (84 in.) Page 248 Page 46 (14)
CA703 Steering Pod Right Sensor - 2995 mm (118 in.) Page 256 Page 30 (3)
CA704 Steering Pod Key Pad Page 251 Page 46 (14)
Page 256
Page 256
Page 256
CA801 Contactor Panel Contactor Panel Components Page 250 Page 30 (4)
Page 258
CA802 Chassis Battery Connector Page 251 Page 12 (7)
Page 259
CA803 Contactor Panel Alarm Selector Page 250 Page 34 (3)
Page 258
TB201 Chassis Dynamic Cable Termination Page 249 Page 16 (8)
Page 251
Page 257
Page 259
TB202 Chassis Dynamic Cable Termination Page 249 Page 16 (8)
Page 251
Page 257
Page 259
TB301 Platform Static Harness Termination Page 248 Page 76 (14)
Page 256
TB302 Platform Static Harness Termination Page 248 Page 76 (8)
Page 256
02 Rev. 10/04
227
GLOSSARY
Contactors/Relays
ED Contactor Panel Emergency Disconnect Page 246 Page 34 (1)

Page 247
Page 250
Page 254
Page 255
Page 258
K1-A Platform Load Tray Lower Page 255
Page 256
K1-B Platform Load Tray Raise Page 255
Page 256
P1 Hydraulic Unit Raise Page 246 Page 22 (1)
Page 247
Page 249
Page 251
Page 254
Page 255
Page 257
Page 259
02 Rev. 10/04
228
GLOSSARY
Diode Blocks
DB11 Platform Platform Diodes Page 248 Page 76 (9)

Page 256
DB22 Chassis MRC1 Protection Page 249 Page 16 (14)
Page 257
Fuses
FU1 Service Panel Control Page 247 Page 44 (10)

Page 249
Page 255
Page 257
FU2 Contactor Panel Traction Page 255 Page 34 (2)
Page 251
Page 255
Page 259
FU3 Contactor Panel Lift Page 255 Page 34 (2)
Page 251
Page 255
Page 259
FU4 Platform Load Tray Raise/Lower Page 255
Page 258
02 Rev. 10/04
229
GLOSSARY
Lights
CHSLF Service Panel Front Strobe Page 246 Page 44 (15)

Page 247
Page 249
Page 254
Page 255
Page 257
PLSLL Platform Left Rear Strobe Page 246 Page 78 (55)
Page 247
Page 248
Page 254
Page 255
Page 256
PLSLR Platform Right Rear Strobe Page 246 Page 78 (55)
Page 247
Page 248
Page 254
Page 255
Page 256
02 Rev. 10/04
230
GLOSSARY
Miscellaneous
BRK1 Traction Motor M1 Left Motor Brake Page 246 Page 16 (6)
Page 247
Page 249
Page 254
Page 255
Page 257
BRK2 Traction Motor M2 Right Motor Brake Page 246 Page 16 (6)
Page 247
Page 249
Page 254
Page 255
Page 257
HM Service Panel Truck Hour Meter Page 246 Page 44 (14)
Page 247
Page 249
Page 254
Page 255
Page 257
R1 Chassis Strobe Trigger Noise Supp. Page 249 Page 44 (20)
Page 257
02 Rev. 10/04
231
GLOSSARY
Motors
M1 Left Drive Unit Left Traction Page 246 Page 16 (6)

Page 247
Page 249
Page 254
Page 255
Page 257
M2 Right Drive Unit Right Traction Page 246 Page 16 (6)
Page 247
Page 249
Page 254
Page 255
Page 257
M3 Hydraulic Unit Lift Page 246 Page 22 (17)
Page 247
Page 251
Page 254
Page 255
Page 259
M4 Platform Load Tray RaiseLower Page 254
Page 255
Page 256
02 Rev. 10/04
232
GLOSSARY
Sensors
LHS Steering Pod Left Presence Sensors Page 246 Page 40 (24)
Page 247
Page 248
Page 254
Page 255
Page 256
POT1 Steering Pod Steering Accelerator Page 246 Page 40 (19)
Page 247
Page 248
Page 254
Page 255
Page 256
POT2 Traction Pod Traction Command Page 246 Page 38 (10)
Page 247
Page 248
Page 254
Page 255
Page 256
RHS Traction Pod Right Presence Sensors Page 246 Page 38 (16)
Page 247
Page 248
Page 254
Page 255
Page 256
TLTS Contactor Panel Tilt Sensor Page 246 Page 34 (13)
Page 247
Page 250
Page 254
Page 255
Page 258
02 Rev. 10/04
233
GLOSSARY
Solenoid Valves
SV1 Hydraulic Unit Lower Page 246 Page 22 (5)

Page 247
Page 249
Page 254
Page 255
Page 257
Suppressor Blocks
SB21 Hydraulic Unit Raise/Lower Page 249 Page 22 (16)

Page 257
SB81 Contactor Panel Alarm Page 250 Page 34 (6)
Page 258
SB82 Contactor Panel Horn Page 250 Page 34 (5)
Page 258
SB83 Contactor Panel Emergency Disconnect Page 250 Page 34 (7)
Page 258
02 Rev. 10/04
234
GLOSSARY
Switches
CHSL1 Platform Left Chain Slack Page 254 Page 66 (40)

Page 255
Page 256
CHSL2 Chassis Left Chain Slack Page 246 Page 64 (4)
Page 247
Page 249
Page 254
Page 255
Page 257
CHSR1 Platform Right Chain Slack Page 254 Page 66 (40)
Page 255
Page 256
CHSR2 Chassis Right Chain Slack Page 246 Page 64 (3)
Page 247
Page 249
Page 254
Page 255
Page 257
DMSL Platform (Floorboard) Left Foot Brake Page 246 Page 80 (2)
Page 247
Page 248
Page 254
Page 255
Page 256
DMSR Platform (Floorboard) Right Foot Brake Page 246 Page 80 (2)
Page 247
Page 248
Page 254
Page 255
Page 256
02 Rev. 10/04
235
GLOSSARY
DTS Service Panel Drive/Tow Page 246 Page 44 (8)

Page 247
Page 249
Page 254
Page 255
Page 257
ECS Service Panel Elevation Control Page 246 Page 44 (8)
Page 247
Page 249
Page 254
Page 255
Page 257
EDS1 Traction Pod Platform Emergency Disconnect Page 246 Page 38 (1)
Page 247
Page 248
Page 254
Page 255
Page 256
EDS2 Service Panel Chassis Emergency Disconnect Page 246 Page 44 (9)
Page 247
Page 249
Page 254
Page 255
Page 257
ERLS Service Panel Emergency Raise/Lower Page 246 Page 44 (7)
Page 247
Page 249
Page 254
Page 255
Page 257
02 Rev. 10/04
236
GLOSSARY
FLMCS Chassis Forward Left Motor Cover Page 246 Page 54 (2)
Page 247
Page 249
Page 254
Page 255
Page 257
FRMCS Chassis Forward Right Motor Cover Page 246 Page 54 (2)
Page 247
Page 249
Page 254
Page 255
Page 257
GCSL Platform Gate Closed Switch Left Page 246 Page 50 (4)
Page 247
Page 248
Page 254
Page 255
Page 256
GCSR Platform Gate Closed Switch Right Page 246 Page 50 (3)
Page 247
Page 248
Page 254
Page 255
Page 256
GOSL Platform Gate Open Switch Left Page 246 Page 50 (3)
Page 247
Page 248
Page 254
Page 255
Page 256
02 Rev. 10/04
237
GLOSSARY
GOSR Platform Gate Open Switch Right Page 246 Page 50 (4)
Page 247
Page 248
Page 254
Page 255
Page 256
HNS Traction Pod Horn Page 246 Page 38 (5)
Page 247
Page 248
Page 254
Page 255
Page 256
HSS Traction Pod High Speed Page 246 Page 38 (13)
Page 247
Page 248
Page 254
Page 255
Page 256
HTS20 Platform 510 mm (20 in.) Sense for Trac- Page 246 Page 52 (2)
tion Cutout
Page 247
Page 248
Page 254
Page 255
Page 256
HTS84 Platform 2135 mm (84 in.) Sense for Trac- Page 254 Page 52 (2)
tion Cutout
Page 255
Page 256
KYS Steering Pod Main Key Page 246 Page 40 (2)
Page 247
Page 248
Page 254
Page 255
Page 256
02 Rev. 10/04
238
GLOSSARY
LOS1 Traction Pod Lower Page 246 Page 38 (4)

Page 247
Page 248
Page 254
Page 255
Page 256
LTS Traction Pod Load Tray Raise/Lower Page 254
Page 255
Page 256
PORS Traction Pod Presence Override Page 246 Page 38 (13)
Page 247
Page 248
Page 254
Page 255
Page 256
RAS1 Traction Pod Raise Page 246 Page 38 (2)
Page 247
Page 248
Page 254
Page 255
Page 256
RCS Platform Raise Cutout Page 246 Page 52 (2)
Page 247
Page 248
Page 254
Page 255
Page 256
RGSL Chassis Rail Guidance Switch Left Page 246
Page 247
Page 249
Page 254
Page 255
Page 257
02 Rev. 10/04
239
GLOSSARY
RGSR Chassis Rail Guidance Switch Right Page 246

Page 247
Page 249
Page 254
Page 255
Page 257
RLMCS Chassis Rear Left Motor Cover Page 246 Page 54 (1)
Page 247
Page 249
Page 254
Page 255
Page 257
RRMCS Chassis Rear Right Motor Cover Page 246 Page 54 (1)
Page 247
Page 249
Page 254
Page 255
Page 257
02 Rev. 10/04
240
GLOSSARY
System/Modules
Location Diagram Parts Breakdown
Battery Charger Chassis Page 246 Page 12 (13)

Page 247
Page 251
Page 254
Page 255
Page 248
CAN Display Steering Pod Page 246 Page 40 (5)
Page 247
Page 248
Page 254
Page 255
Page 256
System Controller (MRC1) Chassis Page 246 Page 12 (16)
Page 247
Page 249
Page 248
Page 254
Page 255
Page 257
Page 259
CHSC - Strobe Controller Chassis Page 249 Page 44 (20)
Page 257
PLSC - Strobe Controller Platform Page 248 Page 78 (54)
Page 256
Key Pad Steering Pod Page 247 Page 40 (14)
Page 248
Page 255
Page 256
02 Rev. 10/04
241
GLOSSARY
Notice:
Printed in Germany
242
ELECTRICAL DIAGRAMS
Printed in Germany
243
ELECTRICAL DIAGRAMS
Notice:
Printed in Germany
244
ELECTRICAL DIAGRAMS
Diagrams (2135 mm, 84 in)

This electrical diagram index lists the diagrams with the
portion of the vehicle covered by each diagram
.
Title Page Number Revision
Block Diagram Page 246 01 - 3/01

Schematic Page 247 03 - 10/04
Pictorial - Platform Page 248 03 - 10/04
Pictorial - Chassis Page 249 01 - 3/01
Schematic - Contactor Panel Page 250 01 - 3/01
Maintenance Free Batteries Page 251 01 - 3/01
Wire Harnesses Page 252 04 - 10/04
WAVE 50 10/2005 • Printed in Germany DIA-2450
04 Rev. 10/04
245
ELECTRICAL DIAGRAMS
Block Diagram
Block Diagram
A B C
L HS
S E NS O R S )
L E F T H AN D
(P R E S E N C E
TR ANS
C O NTR O L
P O T1
RECV
C AN
K YS
DIS P L AY
1 P L ATFO R M 1
TE R MINATIO N
R IG H T H AN D
R HS
S E NS O R S )
(P R E S E N C E
C O NTR O L
TR ANS
LOS 1
E DS 1
R AS 1
P O T2
RECV
POR S
H NS
HS S
P L ATF O R M
H TS 20
G OS L
GCSL
GCSR
DMS L
G OS R
DMS R
RCS
PLS LL PLS LR
2 2
18
P L ATFO R M
C H AS S IS
C HAS S IS HN C HS L F
E R LS
TE R MINATIO N
ECS
HM
- B ATTE R Y
+ S E R VIC E
P ANE L
3 M3
B ATTE R Y
3
C HAR G E R
IN H IB IT
E DS 2 ED
DTS 1
BRK1 BRK2
S YS TE M
C O NTR O L L E R
C HS R C HS L S V1
RGSL
RGSR
TL TS
P1
4 AL M
4
FL MC S R L MC S R R MC S FR MC S
M1 NO TE S :
1. O P TIO NS AR E S H O WN IN DA S H E D B O XE S
M2
A B C
120129A EEC
DIA-2450 WAVE 50 10/2005 • Printed in Germany
01 Rev. 3/01
246
ELECTRICAL DIAGRAMS
Schematic
Schematic
A B C
M3
FU3 P1
ACK40
PC/
CA607-1
CA607-2
CA607-3
CA607-4
HANDSET
GROUND
1 1
TRANS
RCV
12V
CA402-1
CA402-2
CA402-3
CA402-4
B+
B-
FU2 (X2 IN SERIES)
ACK40 CA401-14
SV1 CA401-12 FLMCS (X4 IN SERIES)
LOS1 CHSL FRMCS
DR4
SR8
CHSR RLMCS
RRMCS TILT
LOWER
SENSOR
+BV(ED-B)
ERLS MRC1 CA401-17
RAISE CONTROLLER TLTS
DR2
SR7
P1 CA401-11 CA401-16
RGSL RGSR
DR3
RAS1 RCS
DL6
CA401-19
GCSL GCSR
DL7
CA401-5
CA401-20
SR6
GOSL GOSR
HM CH NEG
2 2
CA401-2 BRK2
CA401-13
MR+ M2
RT TRACT
FILTER CA401-8 MOTOR OUT
MR-
ALM ML+
CH NEG LT TRAC
MOTOR OUT
ML- M1
CA401-1
CA401-7 BRK1
DL2
SR10
CA401-4
CA401-3
PLATFORM NEG
CA401-18
ED CA401-9
INHIBIT
DR5
SR9
EDS1 EDS2
SL2
CAN LO
CAN HI
CH STROBE
DL8
NOT CHARGING, OUT OF RAIL, LEVEL FLOOR, IN HIGH PERF MODE,

DR8
DL3
DL4
CHSLF
2 CIRCUIT OPENS UPON CHARGING, DE-ENERGIZING ED COIL.

PL STROBE 1 VEHICLE SHOWN FULLY LOWERED WITH NO OPERATOR
PRESENT, GATES FULLY OPEN, CONTROL IN PLATFORM,
SL4
SL3
PLSLL PLSLR
3 3
CA701-21
CA701-5
CA701-6
SR11
SL11
POT NEG
3 OPTIONS ARE SHOWN IN DASHED BOXES
POT1
CA701-12 CA701-20 (STEER)
CHASSIS NEG
DMSR PORS PLATFORM COMMAND

NEG
CA701-3 CA701-19
POT POS
SL9
SR2
DMSL
HAND SENSORS ACTIVE
CA701-2
(BLU) RCV OUT POT NEG
SL8
SR3
CA701-17 DISPLAY
SL12
(WHT) RCV IN
+BV(KYS)
CA701-18 CA701-1
DR7
RHS COMMAND
SL10
(ORG) LED OUT

SR1
CA701-13
(GRN) LED IN
CA701-7 CA701-22
NOTES:
POT POS POT2

KEYPAD
PL (TRACTION)
CH KYS CA701-16
(BLU) RCV OUT
ECS CA701-11
SL5
(WHT) RCV IN
CA701-10
LHS CA701-4
(ORG) LED OUT
CA701-8
SL6
(GRN) LED IN
SL1
CA701-9
CA701-15
SL5
HTS20
SR4
SL7
+BV(ED-B)
HSS
DR6
PLATFORM FILTER CA701-14

SR12
NEGATIVE
SR5
4 DL9 4
HNS
DR1
ED-A ED-B
HN
DR9
DL9
2
FU1 DTS
ABC15
BATTERY
CHARGER
+BV (24V)
A B C
120130D EEC
03 Rev. 10/04
247
248
DIA-2450
4
3
2
1
Platform
Platform
CA701
YEL STR POT POS 9.75V=ON
GRN STR POT NEG 2.52V=ON
A
8.75V=FULL LEFT A
-1
LEFT
LEFT
TB301
CA501
CA101
STATIC
RED STR POT WIPER 6.25V=NEUTRAL
POT1
(STRG)
DYNAMIC
3.67V=FULL RIGHT
19 21 20 3
1
1
2902
1
-1 BLK TB201-1 SPARE 2924 2910 2901 KEY SW IN 0V=OPEN, 24V=CLOSED
KYS
2
2
2
-1 WHT TB201-2 +BV(DTS) TO MRC1 2918 2918 2911 2903
2917 LEFT CONTROL POD
3
3
3
-1 RED TB201-3 CAN HI (+5v) TO MRC1 005 005 003 001 CAN HI 0V=OFF, 2.9V=ON
4
4
4
-1 GRN TB201-4 CAN LO (+5v) TO MRC1 006 006 004 002 CAN LO 0V=OFF, 2.9V=ON
5
5
5
-1 ORG TB201-5 SPARE GCSL GCSR 508 504 501 531 BATT NEG 0 VOLTS
507
6
6
6
-1 BLU TB201-6 BATT NEG TO MRC1 5913 5912 5909 5905 5901 HTS20 IN 20V=OPEN, 0V=CLOSED
7
7
7
-1 WHT/BLK TB201-7 BATT NEG TO MRC1 5915 5914 510 5910 5906 5902 HIGH SPD IN 20V=OPEN, 0V=CLOSED
GOSL GOSR 8.75V=FULL FORWARD
8
4 15 14 1
8
8
-1 RED/BLK TB201-8 +BV(ED-B) TO MRC1 2919 104 102 101 TRAC POT WIPER 5.86V=NEUTRAL
3.67V=FULL REVERSE
9
-1 GRN/BLK TB201-9 BATT NEG TO DISPLAY 508 604 602 601 TRAC POT NEG 2.52V=ON
HTS20 704 702 701 TRAC POT POS 9.75V=ON
1
5916
2988 2987 2986 PORS IN 0V=OPEN, 24V=CLOSED
2
511
2 22 12 16
9 10 11 12
2963 902 533 UNUSED 0V=OPEN, 24V=CLOSED
3
2934
PLSLL
CA703
4
2933
BDI
9 10 11 12 13 14
1
RCS 532 GRN
2
CA704
1
2962
PRESENCE
BLK
CA304
BLK
RED
ASM
CA705
WH T
2927
2926
HEIGHT
SWITCH
1
DISPLAY
2901 RED
ELECTRICAL DIAGRAMS
2
1
3
CA306
CA706
2902 KEYPAD
1
FAULT
2903 R/W
BLK
RED
WH T
UNUSED WHT
CA305
WH T RCV IN
1
RED 2989 BLU
WIRES
RCV OUT
STATIC
RCV IN
RCV OUT
LED OUT
LED IN
LHS
CABLES
2
AREA
DYNAMIC
BLK 523 LED IN
LOWER
B
B
GRN
506
104
604
704
PLSC
10 11 9 8
2963
2988
2917
2919
5910
ORG
PLATFORM
2924
7
13
LED OUT
18
17
3
WH T 901
4
GRN 524
BLK
RED
WH T
BLU
GRN
ORG
WH T
2
1
3
BLK
BLK
DB11
CA307
03 Rev. 10/04
CA502
TB302
RIGHT
STATIC
BLK
DMSL
RED
DMSR
1
WH T
3
4
1
2
1
1
ASM
704 703 YEL
2
CA702
SWITCH
DEADMAN
2
2
WH T
WH T
604 603 GRN
3
POT2
BLU
3
3
GRN
ORG
103
WH T
(TRAC)
4
104 RED
PLSLR
1
2
4
4
CA303
5910 5907 5903
-2
5
RIGHT
CA102
HSS
5
5
DYNAMIC
5911 5908 5904 502
2963 HNS
RIGHT CONTROL POD
1
-2 BLK TB202-1 BATT NEG TO HN1 5911 2919
6
6
2920 2912 2904
2
-2 WHT TB202-2 +BV(ED-B) FROM ERLS 2929 2989
RHS
3
7
7
-2 RED TB202-3 +BV(ED-B) TO P+ 2927 2921 2913 2905 513

RAS1
4
8
8
-2 GRN TB202-4 +BV(ED-B) TO SV1+ 2925 2922 2914 2906 2907

LOS1 1 2
5
-2 ORG TB202-5 +BV(DTS) TO EDS2 2923 2923 2915 2908
EDS1 2980
6
-2 BLU TB202-6+ BV(DTS) FROM DTS 2924 2917 2916 2909
PORS 2
7
-2 WHT/BLK TB202-7 +BV(ED-B) FROM ECS 2928 2988 2981 2979
506 1 3
8
9 10 11 12
-2 RED/BLK TB202-8 SPARE 901 523 505 503

509
9
509 524
1
-2 GRN/BLK TB202-9 BATT NEG FROM CHASSIS
C
C
9 10 11 12 13 14
NOTES:
1 REMOVE JUMPER FOR LOW INTENSITY STROBE

2 OPTIONAL KEYPAD: CONNECTS AS SHOWN WHEN
KEYSWITCH IS NOT PRESENT.
4
3
2
1
120132G EEC

4
3
2
1
Chassis
TB201
CA401 1 1 BLK CA101-1 SPARE
0V=OPEN, 24V=CLOSED KEY IN 1 2935 2935 2 -1 WHT CA101-2 +BV(DTS) FROM KYS
0V=OFF, 2.9V=ON CAN HI 4 007 007 3 -1 RED CA101-3 CAN HI (+5V) FROM DISPLAY
0V=OFF, 2.9V=ON CAN LO 3 008 008 4 -1 GRN CA101-4 CAN LO (+5V) FROM DISPLAY
5 -1 ORG CA101-5 SPARE
A
A
20V=OPEN, 0V=CLOSED GATE CLOSED IN 19 5917 5917 6 -1 BLU CA101-6 BATT NEG FROM GCS' S
20V=OPEN, 0V=CLOSED GATE OPEN IN 20 5918 5918 7 -1 WHT/BLK CA101-7 BATT NEG FROM GOS' S
2936
0V=OPEN, 24V=CLOSED DEADMAN IN 13 2937 2937 8 -1 RED/BLK CA101-8 +BV)ED-B) FROM DMS' S
2938
0V=OPEN, 24V=CLOSED ECS CH IN 5 2964 527 9 -1 GRN/BLK CA101-9 BATT NEG TO DISP/HTS20
20V=OPEN, 0V=CLOSED INHIBIT IN 18 5920 5920 10 GRN (POWER) BATT NEG FROM CHARGER
2939
0V=OFF, 24V=ON BRAKE OU T 7 2941 2941 11
2956 -1 DYNAMIC LEFT
FU 1 CA403
ABC15 14

TRACTION 204 1 201 201 CA801-8 +BV FROM ED- A
LEFT OUT EDS2
CA601 2973 2 2947 2947 CA801-1 +BV (DTS) TO ED
1 2
0V=OFF, 24V=ON IN FORWARD ML + 207 1 RED 2974 3 2948
0V=OFF, 11V=ON IN REVERSE ML – 009 2 BLK M1 CA603 2969 4 2955 2955 CA801-4 +BV (ED-B) FROM ED- B
ECS PL 2944
BRK1 BLK 1 2970 5 DB22
2958 CH RAIS E
TRACTION BLK ERLS 2971 6 2945 1
RIGHT OUT 1 LOWE R
CA604 2957 2972 7 2946 2
0V=OFF, 11V=ON IN REVERSE MR – 010 1 BLK DTS PUSH
2966 8 2942 3
301
0V=OFF, 24V=ON IN FORWARD MR + 208 2 RED M2 CA605 202 DRIVE
2967 9 2943
CA602 BRK2 BLK 1 205 10 203 203 CA801-3 +BV TO ED- B
210 1 521 512
HM
BLK 1 11
2
CA606 3 2965 12 2938
13 2964
0V COTROLLER NEGATIVE 2 526 15
AC INLET
CA405 CA404
AC JUMPER
AC CONNECTOR
SILVER TER M WH T
1
BRASS TER M BLK 2 BLK (POWER) AC POWER TO BATTERY CHARGER
SPARE SW HI 6 GREEN TER M GR N
SPARE DR LO 10 1 3 CHASSIS
B
B
STROBE CONTROLLER CA608

SPARE SW LO 15 CA406
RED 1 RED RED 2936
SERVICE BLK 2 BLK CHSC BLK 520 R1
PANEL CA203 CA204
01 Rev. 3/01
WH T 3 WH T WH T 904 1 1
MRC1
1 2 3 4
CHSLF CA407
2 GR N 525
ABNORMAL CHARGE (RED ) 1 RED RED 5 VOLTS FROM CHARGER
CHARGING (YEL ) 2 WH T WHT 5 VOLTS FROM CHARGER
CHARGE COMPLETE (GRN) 3 GR N GRN 5 VOLTS FROM CHARGER
4 BLK BLK BATT NEG FROM CHARGER
24V=OFF, 0V=ON ED OU T 9 5922
5922 CA801-2 BATT NEG TO ED-
24V=OFF, 0V=ON ALARM OU T 8 5932 5932 CA801-7 +24V TO ALM
20V=OPEN, 0V=CLOSED TILT IN 17 5923 5923 CA801-6 BATT NEG FROM TLTS
TB202 5921 CA801-5 BATT NEG TO HN
1 -2 CA102-1 BATT NEG FROM HNS
2945 2 -2 WHT CA102-2 +BV(ED-B) TO RCS
24V=OFF, 0V=ON LIFT OU T 11 5924 P1 2949 3 -2 RED CA102-3 +BV(ED-B) FROM RCS
2946
24V=OFF, 0V=ON LOWER OU T 12 5925 2952 2951 2950 4 -2 GRN CA102-4 +BV(ED-B) FROM LOS1
SV1 CHSL CHSR 2948 5 -2 ORG CA102-5 +BV(DTS) FROM EDS1
5926
2954
1 2943 6 -2 BLU CA102-6 +BV(DTS) TO KYS
2953
2 2944 7 -2 WHT/BLK CA102-7 +BV(ED-B) TO DMS' S
5927
SB21 3
-2 RED/BLK CA102-8 STROBE TRIGGER
4 527
5 FLMCS RLMCS RRMCS FRMCS 518 9 -2 GRN/BLK CA102-9 BATT NEG TO PLATFORM
520
C
C
20V=OPEN, 0V=CLOSED MOTOR COVER IN 14 593 5938 5937 5936 514 10

512 -2 DYNAMIC RIGHT
20V=OPEN, 0V=CLOSED RAIL MODE IN 16 5929 5928 515 11
519 3
RGSL RGSR NOTES: 517 12
CA402 525
CA607
RECEIVE 1 1 1 REPLACE AC JUMPER WITH CABLE REEL WHEN PESENT. 14
COMM GROUND 2 2 517 CA801 9-9 BATT NEG TO TLTS
PORT TRANSMIT 2 CH STROBE CONTROLLER HAS UNUSED CONNECTOR. 519 (POWER) FROM BATTERY NEG POST
3 3 SERVICE 518 (POWER) FROM BATTERY NEG POST
12 VOLTS 4 4 TERMINAL
3 REMOVE JUMPER FOR LOW INTENSITY STROBE.
4
3
2
1
249
Chassis
DIA-2450
120131E EEC
ELECTRICAL DIAGRAMS
250
DIA-2450
4
3
2
1
A
A
Contactor Panel
Contactor Panel
SB83
CA801
2974 CA403-2 +BV(DTS) FROM EDS2 1 2975 ED
5922 CA401-9 BAT NEG FROM MRC1 2 5930
ED-B
203 CA403-10 +BV FROM DTS 3 206 SB82
5955 CA403-4 +BV(ED-B) TO ECS 4 2976 GRN RED
HN 2977 2978
2921 TB202-1 BAT NEG FROM HNS 5 5931
5923 CA401-17 BAT NEG TO MRC1 6 5933 SB81
ELECTRICAL DIAGRAMS
TLTS
5932 CA401-8 BAT NEG FROM MRC1 7 5934 RED 1
ED-A 5933
201 CA403-1 +BV(ED-A) TO FU1 8 209 1 ALM RED 2
CA803
B
B
517 TB202-11 BAT NEG 9 516 RED 3

2 BLK
516 4
GRN
5934 5
01 Rev. 3/01
NOTES:
1 ED-A CIRCUIT ALSO APPEARS ON POWER CABLE PICTORIAL.
2 ROTATE CONNECTOR UNTIL "SET" IS MATCHED TO DESIRED dB LEVEL.
LOW = 77dB
MED = 87dB
HIGH = 97dB
3 CONNECTOR CA802 SHOWN ON POWER CABLE PICTORIAL.
C
C
4
3
2
1
120428B EEC

ELECTRICAL DIAGRAMS
Power Cables
Power Cables
A B C
MAINTENANCE FREE BATTERIES
SERVICE
PANEL
GRN TB201-10
WHT CA407-2
519 TB202-11
GRN CA407-3
RED CA407-1
BLK CA407-4
518 TB202-9
CA404
1 1
TO
+
MRC1
BATT1
BATT4
6V
6V
2 2
AC+
DC+
AC-
DC-
GRD.
LED NEG
GRN LED
RED LED
YEL LED
RED
BLK
519
084568-054
3
084568-054
084568-043
BATTERY
518
+
+
CHARGER
084568-057
+
HYDRAULIC
084568-055
084568-056
3 3
UNIT
BATTERY
BATT2 BATT3 CONNECTOR
6V 6V
+
M3 CA802
084568-051
P1
084568-058
2
084568-046
084568-045
FU 3
ACK40
1
FU 2
ACK40
ED- A
4 4
NOTES:
1 ED-B AND COIL APPEAR ON CONTACTOR PANEL PICTORIA L
2 P1 COIL APPEARS ON CHASSIS PICTORIAL.
3 CIRCUIT OPENS UPON CHARGING, DE-ENERGIZING ED COIL
4 ALL POWER CABLES (84568) ARE #6
5 NEGATIVE POSTS UP ON ALL BATTERIES
A B C
120144C EEC
01 Rev. 3/01
251
ELECTRICAL DIAGRAMS
Wire Harnesses
Wire Harnesses
Harnesses Components Connected By:
120135 Right Pod Harness - JC502, PORS, HSS, EDS, HN, RAS1, LOS1
120136-001 Static Harness L.H. - PC501, TB301
120136-002 Static Harness R.H. - PC502, TB302
120139 Service Panel Harness - FU1, EDS, ECS, HM, DTS, ERLS, JC403
120141 Mast Switch Assembly Harness - PC304, HTS20, RCS
120411 Contactor Panel Harness - SB81, ED-A, ED-B, ED COIL, HN, JC801
125219-001 High Lift Static Harness L.H. - PC501, TB301
125219-002 High Lift Static Harness R.H. - PC502, TB302
126408-001 Dynamic Harness L.H. - PC101, TB201
126408-002 Dynamic Harness R.H. - PC102, TB202
126409-001 High Lift Dynamic Harness L.H. - PC101, TB201
126409-002 High Lift Dynamic Harness R.H. - PC102, TB202
126411 Platform Harness - JC304, JC101, JC305, JC102, TB301, TB302, DB11,
PC303, Right Gate, Left Gate
126412 Chassis Harness - PC801, PC601, JC606, JC605, PC401, JC608,
PC403, PC602, JC603, JC604, TB201, TB202, DB22, SB21, SV1, P1,
FLMCS, RLMCS, RRMCS, CHSL2, CHSR2, ML+, ML-, MR+, MR-
127401 Left Pod Harness - JC501, PC701, PC702, KYS, JC704, JC703
04 Rev. 10/04
252
ELECTRICAL DIAGRAMS

This electrical diagram index lists the diagrams with the
portion of the vehicle covered by each diagram.
.
Title Page Number Revision
Block Diagram Page 254

Schematic Page 255
Pictorial - Platform Page 256
Pictorial - Chassis Page 257
Schematic - Contactor Panel Page 258
Maintenance Free Batteries Page 259
Wire Harnesses Page 260
253
ELECTRICAL DIAGRAMS
Block Diagram
Block Diagram
A B C
LHS
LEFT HAND
(PRESENCE
SENSORS)
CONTROL
CAN
TRANS
POT1
RECV
KYS
DISPLAY
LT S
1 1
PLATFORM
TERMINATION
RIGHT HAND
RHS
(PRESENCE
CONTROL
SENSORS)
TRANS
POT2
LOS1
EDS1
RAS1
HNS
PORS
RECV
HSS
PLATFORM
GOS R
GOS L
M4
DMSR
HTS20
HTS84
DMSL
GCSR
RELAY
GCSL
LOAD
RCS
TRAY
PLSLL PLSLR
2 2
24
PLATFORM
CHASSIS
CHASSIS HN CHSLF
ECS
ERLS
TERMINATION
HM
- BATTERY
SERVICE
+ PANEL
BATTERY
3 M3 3
CHARGER
INHIBI T
EDS2 ED
DTS1
BRK1 BRK2
SYSTEM
CONTROLLER CHSR1 CHSL1 CHSR2 CHSL2 SV1
RGSR
RGSL
TLTS
P1
ALM
4 4
FLMCS RLMCS RRMCS FRMCS
M1
NOTES:
M2 1 OPTIONS ARE SHOWN IN DASHED BOXES
A B C
127290A EEC
254
ELECTRICAL DIAGRAMS
Schematic
Schematic
A B C
M3
FU3 P1
ACK4 0
CA607-1
CA607-2
CA607-3
CA607-4
PC/
HANDSET
GROUND
TRANS
RCV
1 1
12V
CA402-1
CA402-2
CA402-3
CA402-4
B+
B-
FU2 (X2 IN SERIES)
ACK4 0 CA401-1 4
SV1 CA401-1 2 (X4 IN SERIES)
FLMCS
LOS1 CHSL 1 CHSL 2
DR4
FRMCS
SR8
DR11
CHSR1 CHSR2 RLMCS

RRMCS TILT
LOWER SENSOR
+BV(ED-B)
ERL S MRC1 CA401-17
DR2
SR7
RGSL RGSR
P1 CA401-1 1 CA401-16
DR3
RAS1 RCS
DL6
GCSL GCSR
CA401-1 9
CA401-5
DL7
GOSL GOSR
SR6
CA401-2 0
HM CH NEG
2 CA401-1 3
CA401- 2 BRK2 2
MR+ M2
RT TRACT
FILTE R CA401-8 MOTOR OUT
MR-
AL M ML +
CH NEG LT TRAC
MOTOR OUT
ML - M1
CA401-1
CA401- 7 BRK1
DL2
SR10
CA401-4
CA401-3
PLATFORM NEG
CA401-18
ED CA401-9
INHIBIT
DR5
EDS1 EDS2
SR9
CAN LO
CAN HI
CH STROBE
DL8
DR8
DL3
DL4
CHSL F

PL STROBE

SL3
SL4
1 VEHICLE SHOWN FULLY LOWERED WITH NO OPERATOR

PLSLL PLSL R PRESENT, GATES FULLY OPEN, CONTROL IN PLATFORM,
CA701-21
3 3
SR11
CA701-5
CA701-6
SL11
POT NEG
CA701-1 2 CA701-20 POT1
DMSR PORS PLATFORM COMMAND (STEER)

NEG
CHASSIS NEG
CA701-19
SL2
POT POS
SR2
SL9
DMSL CA701-3
CA701-2
(BLU ) RCV OUT POT NEG
SR3
SL10 SL8
CA701-1 7
HAND SENSORS ACTIVE
SL15
(WHT) RCV IN DISPLAY POT2

+BV(KYS)
CA701-1 8 CA701-1
DR7
RHS (ORG) LED OUT COMMAND (TRACTION)

SR1
CA701-1 3
(GRN) LED IN
CA701-7 CA701-22
POT POS
SL13
PL
KEYPAD
NOTES:
KYS CA701-1 6
CH (BLU ) RCV OUT
ECS CA701-1 1 HTS8 4
SL5
(WHT) RCV IN
CA701-1 0
LH S CA701- 4
(ORG) LED OUT
CA701-8
SL1
SL6
SL15
(GRN) LED IN
CA701-9
CA701-15
HTS2 0
SR4
SL7
DL9
DR6
PLATFORM CA701-14
+BV(ED-B)
FILTE R
SR12
NEGATIVE
DR1
HSS
SR5
DL 9
HN HNS
ED- A MOTORIZED LOADTRAY
4 4
SR13
ED- B
K1-B
SR1 4
FU1 K1-A
SR1 5 LT S
ACB15 DTS
FU4 RAISE 2
DR10
M4 BATTERY
ABC1 5 DR1 2 LOWER CHARGER
+BV (24V )
A B C
127288A EEC
255
ELECTRICAL DIAGRAMS
Platform
Platform
A B C
M3
FU3 P1
ACK4 0
CA607-1
CA607-2
CA607-3
CA607-4
PC/
HANDSET
GROUND
TRANS
RCV
1 1
12V
CA402-1
CA402-2
CA402-3
CA402-4
B+
B-
FU2 (X2 IN SERIES)
ACK4 0 CA401-1 4
SV1 CA401-1 2 (X4 IN SERIES)
FLMCS
LOS1 CHSL 1 CHSL 2
DR4
FRMCS
SR8
DR11
CHSR1 CHSR2 RLMCS

RRMCS TILT
LOWER SENSOR
+BV(ED-B)
ERL S MRC1 CA401-17
DR2
SR7
RGSL RGSR
P1 CA401-1 1 CA401-16
DR3
RAS1 RCS
DL6
GCSL GCSR
CA401-1 9
CA401-5
DL7
GOSL GOSR
SR6
CA401-2 0
HM CH NEG
2 CA401-1 3
CA401- 2 BRK2 2
MR+ M2
RT TRACT
FILTE R CA401-8 MOTOR OUT
MR-
AL M ML +
CH NEG LT TRAC
MOTOR OUT
ML - M1
CA401-1
CA401- 7 BRK1
DL2
SR10
CA401-4
CA401-3
PLATFORM NEG
CA401-18
ED CA401-9
INHIBIT
DR5
EDS1 EDS2
SR9
CAN LO
CAN HI
CH STROBE
DL8
DR8
DL3
DL4
CHSL F

PL STROBE

SL3
SL4
1 VEHICLE SHOWN FULLY LOWERED WITH NO OPERATOR
PLSL R
PRESENT, GATES FULLY OPEN, CONTROL IN PLATFORM,
PLSLL
CA701-21
3 3
SR11
CA701-5
CA701-6
SL11
POT NEG
CA701-1 2 CA701-20 POT1
DMSR PORS PLATFORM COMMAND (STEER)

NEG
CHASSIS NEG
CA701-19
SL2
POT POS
SR2
SL9
DMSL CA701-3
CA701-2
(BLU ) RCV OUT POT NEG
SR3
SL10 SL8
CA701-1 7
HAND SENSORS ACTIVE
SL15
(WHT) RCV IN DISPLAY POT2

+BV(KYS)
CA701-1 8 CA701-1
DR7
RHS (ORG) LED OUT COMMAND (TRACTION)

SR1
CA701-1 3
(GRN) LED IN
CA701-7 CA701-22
POT POS
SL13
PL
KEYPAD
NOTES:
KYS CA701-1 6
CH (BLU ) RCV OUT
ECS CA701-1 1 HTS8 4
SL5
(WHT) RCV IN
CA701-1 0
LH S CA701- 4
(ORG) LED OUT
CA701-8
SL1
SL6
SL15
(GRN) LED IN
CA701-9
CA701-15
HTS2 0
SR4
DR1 SL7
DL9
DR6
PLATFORM CA701-14
+BV(ED-B)
FILTE R
SR12
NEGATIVE HSS
SR5
DL 9
HN HNS
ED- A MOTORIZED LOADTRAY
4 4
SR13
ED- B
K1-B
SR1 4
FU1
K1-A LT S
SR1 5
ACB15 DTS
FU4 RAISE 2
DR10
M4 BATTERY
ABC1 5 DR1 2 LOWER CHARGER
+BV (24V )
A B C
127291B EEC
256
4
3
2
1
Chassis
TB201
CA401 1 -1 BLK CA101-1 SPARE
0V=OPEN, 24V=CLOSED KEY IN 1 2935 2935 2 -1 WHT CA101-2 +BV(DTS) FROM KYS
0V=OFF, 2.9V=ON CAN HI 4 007 007 3 -1 RED CA101-3 CAN HI (+5V) FROM DISPLA Y
0V=OFF, 2.9V=ON CAN LO 3 008 008 4 -1 GRN CA101-4 CAN LO (+5V) FROM DISPLAY
5 -1 ORG CA101-5 SPAR E
20V=OPEN, OV=CLOSED GATE CLOSED IN 19 5917 5917 6 -1 BLU CA101-6 BATT NEG FROM GCS'S
A
A
20V=OPEN, 0V=CLOSED GATE OPEN IN 20 5918 5918 7 -1 WHT/BLK CA101-7 BATT NEG FROM GOS'S
2936
0V=OPEN, 24V=CLOSED DEADMAN IN 13 2937 2937 8 -1 RED/BLK CA101-8 +BV(ED-B) FROM DMS'S
2938
0V=OPEN, 24V=CLOSED ECS CH IN 5 2964 527 9 -1 GRN/BLK CA101-9 BATT NEG TO DISP/HTS20
20V=OPEN, 0V=CLOSED INHIBIT IN 18 5920 5920 10 GRN (POWER) BATT NEG FROM CHARGE R
2939
0V=OFF, 24V=ON BRAKE OUT 7 2941 2941 11
2956
FU 1 CA403
ABC15
TRACTION 204 1 201 201 CA801-8 +BV FROM ED-A

LEFT OUT EDS2
CA601 2973 2 2947 2947 CA801-1 +BV(DTS) TO ED
1 2
0V=OFF, 0-24V=ON IN FORWARD ML + 207 1 RE D 2974 3 2948
0V=OFF, 0-11V=ON IN REVERSE ML - 009 2 BLK M1 CA603 2969 4 2955 2955 CA801-4 +BV(ED-B) FROM ED- B
1 EC S PL 2970 5 2944 DB22
BRK1 BLK
2958 CH RAIS E
TRACTION BLK 1 ERLS 2971 6 2945 1
RIGHT OUT CA602 LOWE R
2957 2972 7 2946 2
CA604 PUSH
0V=OFF, 0-11V=ON IN REVERSE MR- 010 1 BLK 301 DT S 8 2942 3
2966
MR+ 208 2 M2 202 DRIVE
0V=OFF, 0-24V=ON IN FORWARD RE D CA605 2967 9 2943
BRK2 BLK 1 205 10 203 203 CA801-3 +BV TO ED- B
1 210 1 521 11 512
BLK HM
3 2
CA606 2965 12 2938 12 -1 ORG/BLK CA101-10 SPAR E
13 2964 13 -1 BLU/BLK CA101-11 SPAR E
0V CONTROLLER NEGATIVE 2 526 15 14 -1 BLK/WHT CA101-12 SPARE
CA405 AC INLET CA404 AC CONNECTOR -1

AC JUMPER 1 DYNAMIC
SILVER TER M WH T LEFT
6 BRASS TER M BLK 2 BLK (POWER) AC POWER TO BATTERY CHARGER
SPARE SW HI
SERVICE PANEL
GREEN TER M GR N
1
10 3 CHASSIS
SPARE DR LO
B
B
STROBE CONTROLLER CA608

SPARE SW LO 15 CA406
RE D 1 RE D RE D 1 2936
MRC1
BLK 2 BLK CHSC BLK 2 520 CA203 CA204
CHSLF
WH T 3 WH T WH T 3 904 1 1
2
CA407 GR N 4 525 R1
ABNORMAL CHARGE (RED ) 1 RE D RED 5 VOLTS FROM CHARGER

CHARGING (YEL) 2 WH T WHT 5 VOLTS FROM CHARGE R
CHARGE COMPLETE (GRN) 3 GR N GRN 5 VOLTS FROM CHARGER
4 BLK BLK BATT NEG FROM CHARGE R
5921 CA801-5 BATT NEG TO HN
24V=OFF, 0V=ON ED OUT 9 5922 5922 CA801-2 BATT NEG TO ED -
24V=OFF, 0V=ON ALARM OUT 8 5932 5932 CA801-7 +24V TO AL M
TB202
20V=OPEN, 0V=CLOSED TILT IN 17 5923 5923 CA801-6 BATT NEG FROM TLTS
1 -2 BLK CA102-1 BATT NEG FROM HNS
2945 2 -2 WHT CA102-2 +BV(ED-B) TO RCS
24V=OFF, 0V=ON LIFT OUT 11 5924 P1 2949 3 -2 RED CA102-3 +BV(ED-B) FROM RC S
24V=OFF, 0V=ON LOWER OUT 12 5925 SV1 2952 2951 2950 4 -2 GRN CA102-4 +BV(ED-B) FROM LOS1
CHSL2 CHSR2 2948 -2 ORG CA102-5 +BV(DTS) FROM EDS 1
5
SB21
2954
5926
2953
5927
1 2943 6 -2 BLU CA102-6 +BV(DTS) TO KYS
2 2944 7 -2 WHT/BLK CA102-7 +BV(ED-B) TO DMS'S
3
4 -2 RED/BLK CA102-8 STROBE TRIGGE R
5 8 -2 GRN/BLK CA102-9 SPAR E
C
C
20V=OPEN, 0V=CLOSED MOTOR COVER IN 14 5939 527 9 -2 ORG/BLK CA102-10 BATT NEG TO PLATFORM
520 518 (POWER) FROM BATTERY NEG POST
20V=OPEN, 0V=CLOSED RAIL MODE IN 16 5929 5928 5938 5937 5936 514 10
RGSL RGSR FLMCS RLMCS RRMCS FRMCS 512 519 (POWER) FROM BATTERY NEG POST
COMM 515 11 517 CA801-9 BATT NEG TO TLTS
3
PORT CA402 525 12

RECEIV E 1 1 CA607 2946 13 -2 BLU/BLK CA102-11 +BV(ED-B) TO CHS PLATFORM
GROUND 2 2 SERVICE NOTES: 14 -2 BLK/WHT CA102-12 +BV(FU4) TO OPTIONAL M4
3 3 TERMINAL 1 REPLACE AC JUMPER WITH CABLE REEL WHEN PRESEN T
TRANSMIT 212 +BV FROM FU 4
2 CH STROBE CONTROLLER HAS UNUSED CONNECTOR
12 VOLTS 4 4 3 REMOVE JUMPER FOR LOW INTENSITY STROBE -2
DYNAMIC
RIGHT
4
3
2
1
257
Chassis
DIA-2450
127292 AEEC
ELECTRICAL DIAGRAMS
ELECTRICAL DIAGRAMS
Contactor Panel
Contactor Panel
A B C
1 1
SB83
CA801
2947 CA403-2 +BV(DTS) FROM EDS2 1 2975 ED
5922 CA401-9 BATT NEG FROM MRC1 2 5930

ED-B
203 CA403-10 +BV FROM DTS 3 206 SB82
4 2976 GR N RE D
2955 CA403-4 +BV(ED-B) TO ECS
HN 2977 2978
2 5921 TB202-1 BATT NEG FROM HNS 5 5931 2
5923 CA401-17 BATT NEG TO MRC1 6 5933 SB81
5932 CA401-8 BATT NEG FROM MRC1 7 5934 TLTS RE D 1

ED-A 5933
201 CA403-1 +BV(ED-A) TO FU1 8 209 1 ALM WH T 2
CA803
517 TB202-11 BATT NEG 9 516 RED 3
2 BL K
212 TB202-14 +BV(ED-A) TO M4 516 4
FU 4 GR N
15A 5934 5
3 3
NOTES:
1 ED-A CIRCUIT ALSO APPEARS ON POWER PICTORIAL.
2 ROTATE CONNECTOR UNTIL 'SET' IS MATCHED TO DESIRED dB LEVEL:
LOW = 77 dB
MED = 87 dB
HIGH = 97 dB
3 CA802 SHOWN ON POWER CABLE DRAWING
4 4
A B C
127293A EEC
258
ELECTRICAL DIAGRAMS
Power Cables
Power Cables
A B C
MAINTENANCE FREE BATTERIES
SERVICE
PANEL
GRN TB201-10
WHT CA407-2
519 TB202-11
GRN CA407-3
RED CA407-1
BLK CA407-4
518 TB202-9
CA404
1 1
TO
+
MRC1
BATT1
BATT4
6V
6V
2 2
AC+
DC+
AC-
DC-
GRD.
LED NEG
GRN LED
RED LED
YEL LED
RED
BLK
519
084568-054
3
084568-054
084568-043
BATTERY
518
+
+
CHARGER
084568-057
+
HYDRAULIC
084568-055
084568-056
3 3
UNIT
BATTERY
BATT2 BATT3 CONNECTOR
6V 6V
+
M3 CA802
084568-051
P1
084568-058
2
084568-046
084568-045
FU 3
ACK40
1
FU 2
ACK40
ED- A
4 4
NOTES:
1 ED-B AND COIL APPEAR ON CONTACTOR PANEL PICTORIA L
2 P1 COIL APPEARS ON CHASSIS PICTORIAL.
3 CIRCUIT OPENS UPON CHARGING, DE-ENERGIZING ED COIL
4 ALL POWER CABLES (84568) ARE #6
5 NEGATIVE POSTS UP ON ALL BATTERIES
A B C
120144C EEC
259
ELECTRICAL DIAGRAMS
Wire Harnesses
Wire Harnesses
Harnesses Components Connected By:
120139 Service Panel Harness - FU1, EDS, ECS, HM, DTS, ERLS, JC403
120411 Contactor Panel Harness - SB81, ED-A, ED-B, ED COIL, HN, JC801
126412 Chassis Harness - PC801, PC601, JC606, JC605, PC401, JC608, PC403, PC602, JC603,
JC604, TB201, TB202, DB22, SB21, SV1, P1, FLMCS, RLMCS, RRMCS, CHSL2, CHSR2,
ML+, ML-, MR+, MR-
127296 Left Pod Harness - JC501, JC703, PC701, KYS
127297 Right Pod Harness - JC502, PORS, HSS, LTS, EDS, HN, RAS1, LOS1
127298 Platform Harness - CHSL1, CHSR1, JC101, JC304, JC305, JC102, TB301, TB302, PC303,
DB11, Left Gate, Right Gate
127299 Mast Switch Assembly Harness - PC304, RCS, HTS84, HTS20
127300 Sensor Harness
127301-001 Static Harness L.H. - PC501, TB301 2995 mm (118 in.)
127301-002 Static Harness R.H. - PC502, TB302 2995 mm (118 in.)
127302-001 Dynamic Harness L.H. - PC101, TB201 2995 mm (118 in.)
127302-002 Dynamic Harness R.H. - PC102, TB202 2995 mm (118 in.)
260

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MAINTENANCE MANUAL

Order Number: 812562-006

CROWN Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

All rights reserved under international and Pan-American Copyright Agreement.

MA- SAFETY INSTRUCTIONS PAGE

M1- LUBRICATION & ADJUSTMENT PAGE

WAVE 50 10/2005 • Printed in Germany

M3- DRIVE UNIT PAGE

M4- ELECTRICAL MAINTENANCE PAGE

WAVE 50 10/2005 • Printed in Germany

WAVE 50 10/2005 • Printed in Germany

M5- BRAKE MAINTENANCE PAGE

M7- MAST MAINTENANCE PAGE

M8- CYLINDER MAINTENANCE PAGE

WAVE 50 10/2005 • Printed in Germany

DIA- ELECTRICAL DIAGRAMS PAGE

WAVE 50 10/2005 • Printed in Germany

General maintenance – Use chocks or other positive positioning de-

z A scheduled planned maintenance, lubrication and Warning! Fire hazard!

– Remove key. z Keep shop well ventilated, clean and dry.

WAVE 50 10/2005 • Printed in Germany MA-2450

MA-2450 WAVE 50 10/2005 • Printed in Germany

Equipment Cleaning Functional integrity of contaminated components may

WAVE 50 10/2005 • Printed in Germany MA-2450

z Review the appropriate sections in this service Danger! Risk of explosion!

MA-2450 WAVE 50 10/2005 • Printed in Germany

Warning! Risk of property damage!

Gas formed during charging is

z Make certain battery used meets weight, size and

WAVE 50 10/2005 • Printed in Germany MA-2450

Caution! Risk of short-circuit! Warning! Risk of injury!

Warning! Risk of property damage!

NEVER operate truck with an

z Lockout or tagout truck as described in Battery -

MA-2450 WAVE 50 10/2005 • Printed in Germany

z remove the main power fuses,

z install a lockout device on the trucks battery con-

z or if possible install a tag with a cable tie on the

1 Key switch, OFF

z Always turn key (2) switch to "off" (1), remove key

When maintenance is performed and the batteries are

z remove the main power fuses and

z install a commercially available lockout device on

WAVE 50 10/2005 • Printed in Germany MA-2450

1 Load tray 2 Platform

MA-2450 WAVE 50 10/2005 • Printed in Germany

z Move vehicle to a secure non traffic maintenance z Lower platform completely.

Tool Properties Value Crown Part

Capacity: 3620 kg (8000 lb) 122599

1 Hydraulic jack 2 Hardwood block

WAVE 50 10/2005 • Printed in Germany MA-2450

1 Straps 6 Second Stage Mast

MA-2450 WAVE 50 10/2005 • Printed in Germany

WAVE 50 10/2005 • Printed in Germany MA-2450

MA-2450 WAVE 50 10/2005 • Printed in Germany

ble a qualified mechanic to locate and solve problems

Operator instructions -001 German -004 Dutch

Additional copies can be ordered if required. These

WAVE 50 10/2005 • Printed in Germany 22450

Model number example

1 Image generator – Work Assist Vehicle

22450 WAVE 50 10/2005 • Printed in Germany

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