Yearly Maintenance – Crown WR 5000 Forklift
Comprehensive annual procedure to ensure safe, reliable, and OSHA/ISO-compliant operation of the WR 5000 electric forklift.
Battery & Electrical System Overhaul
- Conduct battery load and capacity test
- Inspect and replace corroded terminals
- Test and calibrate charger output and logic
- Replace damaged cables or connectors
- Perform software update for control systems
Hydraulic & Fluid Systems
- Drain and replace hydraulic oil with OEM fluid
- Change hydraulic filters and flush system
- Pressure test and calibrate relief valve
- Replace cracked or leaking hoses
- Inspect brake fluid levels and refill if needed
Fork, Mast, and Lift System Service
- Replace forks if heel wear exceeds limit
- Lubricate mast rollers, rails, and tilt system
- Check chain tension and replace if worn
- Inspect cylinder seals and replace if damaged
- Test lift and tilt performance under load
Structural & Frame Integrity
- Inspect chassis and weld joints for cracks
- Evaluate overhead guard and safety labels
- Assess paint and corrosion areas for touch-up
- Check counterweight attachment and mount points
- Clean and test visibility aids (mirrors, guards)
Operational & Safety Systems
- Perform OSHA 1910.178 full safety compliance test
- Verify e-stop, horn, alarms, and warning lights
- Check operator compartment access and restraint system
- Test speed control, steering and braking
- Document and certify yearly safety compliance
Performance Benchmarking
- Capture baseline data: travel/lift speeds, battery duration
- Compare with previous year's records for performance shift
- Run diagnostics and log any fault codes
- Generate maintenance report with improvement plan
- Update operator certification and training log