PDF Service Manual Crown C-5 Series Pneumatic Engine Forklift - 5 MB
This service manual is dedicated to the Crown C-5 Series forklift with a pneumatic engine.
It contains in-depth information for service technicians, covering everything from routine maintenance to complete engine and transmission overhauls.
Use this factory manual to ensure all repairs are performed to Crown's high standards.
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--- Page 1 ---
INTRODUCTION
Introduction
Introduction
This manual is for qualified service technicians who
have been appropriately trained to do troubleshooting
and maintenance procedures on the lift truck. The
manual contains information about maintenance, trou-
bleshooting, and replacement parts.
Operator instructions
Operator instructions ensure that you and your person-
nel know how to operate your Crown lift truck safely.
These instructions are provided in tag or booklet form
with each lift truck and are not included in this manual.
More copies can be ordered if necessary. For operator
instructions, see the Operator Manual C-5 Series.
Operator training
Crown has operator training programs that are avail-
able through your Crown dealer. For more information
on operator training, consult your Crown dealer or visit
www.crown.com.
Service training
Service training is available for:
• All Crown lift trucks
• Module systems
• Hydraulic systems
• Electrical systems
For more information on service training, consult your
Crown dealer or visit www.crown.com.
Replacement parts
To ensure correct and fast service, always provide the
following information when contacting Crown for re-
placement parts:
• The part number
• The lift truck model number
• The lift truck serial number
• The lift truck data number
Consult your Crown dealer or visit www.crown.com for:
• Current service manuals
• Current operator manuals
• Operator and service training
• Lift truck capacities
• Lift truck specifications
Crown 2017 PF27776 ITD-2515-001
27
--- Page 3 ---
SAFETY
General Maintenance Instructions
General Maintenance Instructions
WARNING
To prevent serious risk of injury to yourself and others,
observe the following safety instructions.
Power industrial trucks may become hazardous if ade-
quate maintenance is neglected. Therefore, adequate
maintenance facilities, trained personnel and proce-
dures should be provided.
Maintenance and inspection shall be performed in con- 1 Remove Key
formance with the following practices: 2 Place Tag on Steering Wheel
1. A scheduled planned maintenance, lubrication, 3 Place Tag on LPG Tank Valve
and inspection system should be followed.
Figure 17264-01
2. Only qualified and authorized personnel shall be
– Chock all four wheels of the truck.
permitted to maintain, repair, adjust and inspect
the truck. – Disconnect the negative (-) battery cable.
3. Before working on the truck: – Block the load engaging means, inter masts, or
chassis before working under them.
– Move the truck to a secure non-traffic mainte-
nance area with a level floor and adequate 4. Before starting to operate the truck:
clearance to check performance of the truck
– Remove the blocks from load engaging means,
and/or its attachments.
inter masts, or chassis (if applicable).
– Fully lower the load engaging means.
– Remove the chocks from the wheels.
– Place the directional controls in neutral.
– Connect the negative (-) battery cable.
– Apply the parking brake.
– Open the LPG tank valve.
– Place the key switch in the OFF position.
– Remove tags from steering wheel and LPG
– Close the LPG tank valve. tank valve that were previously placed there to
warn others that the truck was being serviced.
– Start the truck and fully expend any gas re-
maining in the supply lines. – Be in operating position.
– Place the key switch in the OFF position and – Release the parking brake, if applicable.
remove the key (if applicable). See Figure
– Fasten the seat belt and pull it snug.
17264-01.
– Adjust operator seat and steering wheel to their
– Place tags on steering wheel and LPG tank
most comfortable positions.
valve to warn others that the truck is being ser-
viced. See Figure 17264-01. NOTE: If repairs – Apply the brake.
require you to leave the presence of the truck
– Place the directional control in neutral.
then the truck should be locked out in addition
to being tagged out. Locking out the truck can – Place the key switch in the ON position.
be achieved by disconnecting the gas hose
– Check to make sure that the seat alarm and all
from the LPG tank and placing a locking device
the indicator lights work properly.
on the hose coupling.
– Check functions of lift systems, directional con-
trol, speed control, steering warning devices,
brakes, and any attachments (if applicable).
RST50 2008 PF17272-1 Rev. 10/08 MA-2510-001
01 Rev. 10/08
3
--- Page 4 ---
SAFETY
Control of Hazardous Energy
11. Tow the lift truck at no more than 3.2 k/hr (2 mph) • Lift straps
to a secure maintenance area with a level surface. – Commercially available
Note: Make sure that you allow enough stopping dis- – Capacity: 900 kg (2,000 lb)
tance for the lift truck to coast to a stop. • Hardwood blocks
12. Tagout the towed lift truck. Follow all instructions in – Choose from the following types of hardwood
the Tagout procedures. blocks: oak, hickory, or maple
– 100 x 100 mm x 200 mm (4 x 4 x 8 in)
Lifting and blocking the lift truck
Note: Do not use softwood such as poplar or pine to
Recommended tools and equipment: block the lift truck.
• Hydraulic jack (see Figure 11) • Composite blocks (see Figure 13)
– Capacity: 3,992 kg (8,800 lb) – Crown part number: 061142-001
– Crown part number: 300084 – 89 x 64 x 229 mm (3.5 x 2.5 x 9 in)
– Minimum collapsed height: 60 mm (2.25 in) – Crown part number: 061142-002
– Maximum raised height: 400 mm (16 in) – 89 x 64 x 330 mm (3.5 x 2.5 x 13 in)
– Crown part number: 061143-001
– 100 x 100 x 600 mm (4 x 4 x 22 in)
– Crown part number: 061143-002
– 100 x 100 x 1,219 mm (4 x 4 x 48 in)
Fig. 11 (31988)
• Jack stand (see Figure 12)
– Crown part number: 300081
– Capacity: 6,350 kg (14,000 lb)
Fig. 13 (31990)
• Wheel chocks (see Figures 14 and 15)
– Crown part number: 340094-003
– 127 x 102 x 203 mm (5 x 4 x 8 in)
Fig. 12 (31989)
Fig. 14 (31991)
MA-2515-008 Crown 2017 PF27808
01 Rev. 11/20
12
--- Page 5 ---
INSPECTION AND LUBRICATION
Lubricants, Aerosols, and Service Supplies
Lubricant Identification
Lubricant Description Part Package
Identifier Number Quantity
063002-024 14.5 oz cartridge
F Gear grease
063002-022 35 lb pail
Lubricant - chain and cable 363107-001 15 oz can
G
Lubricant, premium - chain and cable 363115-001 12 oz can
H Protectant - rubber and vinyl 363129-001 11 oz can
063002-039 1 lb
I Grease, synthetic - motor spline connection
127801S 1 oz
063004-002 12 oz
J Fluid, brake, DOT 5
063004-003 1 gal
063002-034 14 oz cartridge
K Grease - wheel bearing
063002-045 40 - 14 oz cartridges
L Lubricant, metal spray, break-in 063002-021 16 oz spray
LL Lubricant, S00727 - freezer condition 063002-059 9 oz can
M Grease, clear - O-rings 063002-020 5.3 oz tube
Cleaner, low VOC - brakes and parts 363119-001 15 oz can
N
Cleaner, nonflammable - brake and parts 363116-001 18 oz can
O Lubricant, penetrating 363104-001 15 oz can
P Grease, premium, multi-purpose 363108-001 13 oz can
Q Grease, white, lithium 363110-001 14 oz can
R Cleaner - carburetor and choke 363109-001 14 oz can
Cleaner, contact, nonflammable 363106-001 10 oz can
S
Cleaner, contact 363128-001 13.5 oz can
127189-001 55 cc
T Contact lubricant
127189-002 2 oz. tube
U Cleaner - battery 363124-001 18 oz can
V Protector - battery 363125-001 14 oz can
W Lubricant, food grade, machine 363127-001 12 oz can
X Lubricant, food grade, silicone spray 363126-001 11 oz can
363535-101 1 gal
Y Coolant, extended lift - C-5 LP series
363535-005 6 - 1 gal bottles
Z Fluid, windshield washer, protects to -29 °C (-20 °F) 300100-101 1 gal
M1.0-04.0-051 Crown 2011 PF25240 Rev. 1/22
07 Rev. 1/22
40
--- Page 6 ---
INSPECTION AND LUBRICATION
Planned Maintenance
Visual inspections, operational
checks, and test drive
Visual Inspections
System Component Service Required
General Overall Examine the lift truck for bent, damaged, or missing parts
Check the following items for leaks:
• Hydraulic hoses and fittings
• Cylinders
• Cooling system or radiator
• Differential
Fluids and lubricants
• Engine
• Transmission
• Fuel system
• Brake system
• Attachments
Check the following items:
• Condition of the tires and wheels
Tires and wheels
• Tire pressure, if applicable
• Loose or missing fasteners
Do a visual inspection for bent, cracked, or badly worn parts.
Forks and fork latches
Make sure that the forks are securely attached
Check the following items:
• Mounting
• Chains
• Pulleys
Mast assembly
• Cables
• Hoses
• Chain anchors
• Chain tension
Stops and stop pads Check the condition and the function of the stops and stop pads
Overhead guard Check the mounting and examine for bends or damage
Safety decals and Check the condition and examine for missing or damaged decals and
capacity plates plates
Seat belt / shoulder and Check the condition and the operation of the restraints. Examine for
hip restraints missing or damaged restraints
Covers, shields, floor- Check the condition and the operation. Examine for missing or dam-
mats, and latches aged parts or fasteners
Check the following items for debris:
Debris / shrink wrap • Wheels, tires, and axles
• Fan and radiator
Brakes Brake pedal Check the condition and the operation
Display lights and hour Check the condition of all the lights and the indicators
Electrical
meter
Crown 2017 PF27778 M1.0-2515-054
49
--- Page 7 ---
INSPECTION AND LUBRICATION
Planned Maintenance
1,000 Hour inspection table
Planned Maintenance Inspection – 1,000 Hour Interval (Approximately 6 Months)
Complete all items on the 500 Hour Interval schedule plus the following:
Index Component Lubri- Quantity Service Required
cant
Type
I-1 Differential drive axle oil A AR Check the oil level
These published maintenance intervals are for typical application. Harsh environment and / or extreme applications require more
frequent maintenance intervals
Lubrication intervals must be changed to a frequency that minimizes corrosion and wear on moving parts for lift trucks operated
in environments with much dust and moisture, or freezer condition applications
See the appropriate section of the service and parts manual for additional information concerning maintenance procedures
1,000 Hour lubrication table
Planned Maintenance Lubrication – 1,000 Hour Interval (Approximately 6 Months)
Complete all items on the 500 Hour Interval schedule plus the following:
Index Component Lubri- Quantity Service Required
cant
Type
L-1 Seat deck latch and hinges O AR Lubricate the latch and the hinges
L-2 Seat slides Q AR Lubricate the seat slides
Engine oil 7.7 l (1)
L-3 CC Change the oil
(dipstick and drain plug shown) (8 qt)
L-4 Engine oil filter N/A N/A Change the oil filter
(1) Includes the oil filter change
AR - As Required
N/A - Not Applicable
See the INSPECTION AND LUBRICATION / Lubricants, Aerosols, and Service Supplies section in the service and parts manual
These published maintenance intervals are for typical application. Harsh environment and / or extreme applications require more
frequent maintenance intervals
Lubrication intervals must be changed to a frequency that minimizes corrosion and wear on moving parts for lift trucks operated
in environments with much dust and moisture, or freezer condition applications
See the appropriate section of the service and parts manual for additional information concerning maintenance procedures
Crown 2017 PF27778 M1.0-2515-064
59
--- Page 8 ---
INSPECTION AND LUBRICATION
Lubricants, Aerosols, and Service Supplies - Internal Combustion
Lubricants, Aerosols, and
Service Supplies - Internal
Combustion
See the Lubricant Identification table and the Alternate
Lubricants and Fluids table in this section for the rec-
ommended list of lubricants, aerosols, and service sup-
plies. Use the tables when performing planned mainte-
nance on Crown LPG lift trucks.
Lubricant Identification
Lubricant Description Part Package
Identifier Number Quantity
363506-001 1 qt
A Oil, gear, 80W-90, requires Extreme Pressure (EP)
363506-012 12 - 1 qt bottles
363513-001 1 qt
AAA Fluid, universal hydraulic and transmission
363513-012 12 - 1 qt bottles
063002-034 14.5 oz cartridge
B Grease, multi-purpose
063002-045 40 - 14.5 oz cartridges
063002-017 14.5 oz cartridge
BB Grease, multi-purpose, low temperature
063002-046 40 - 14.5 oz cartridges
363002-001 14 oz cartridge
BBB Grease, food grade, multi-purpose
363002-030 30 - 14 oz cartridges
063002-025 14.5 oz cartridge
BBBB Grease, multi-purpose, premium
063002-026 5 gal
5B Grease, NLGI 00 063002-060 16 oz can
363500-001 1 qt
C Oil, engine LPG, 10W30
363500-012 12 - 1 qt bottles
363504-101 1 gal
D Oil, standard, hydraulic
363504-106 6 - 1 gal bottles
063002-024 14.5 oz cartridge
E Grease - mast channel and gears
063002-022 35 lb (15.9 kg) pail
363143-001 10.5 oz can
EE Lubricant - channel slide
363143-012 12 - 10.5 oz cans
063002-024 14.5 oz cartridge
F Grease, gear
063002-022 35 lb (15.9 kg) pail
Crown 2021 PF28425 Rev. 12/21 M1.01-2510-001
01 Rev. 12/21
39
--- Page 9 ---
COMPONENTRY
A1
A1 Function: supplies an audible warning to the general
area
Access 1 Data: the horn operates when you push the button in
the center of the steering wheel or on the optional rear
Location: on the left side of the console post handle
Function: displays lift truck information and allows the
Adjustment: point the bell of the horn down
service technician to modify the lift truck settings, cali-
brate components, and troubleshoot Diagrams: DIA-2515-003 (B-2) (509)
DIA-2515-016 (C-1) (522)
Data: information received from the lift truck control
modules and the sensors Parts Breakdown: 04.0-2515-001 (5) (883)
04.0-2615-050 (4) (911)
Adjustment: N/A
Diagrams: DIA-2515-003 (C-3) (509)
DIA-2515-009 (C-1) (515)
Parts Breakdown: 04.8-2515-001 (1) (893)
04.8-2615-001 (1) (925)
A3
Access 3™
Location: below the seat deck in front of Access 4
Function: engine control unit (ECU)
Data: information received from the lift truck control
modules and the sensors
Adjustment: N/A
Diagrams: DIA-2515-010 (C-1) (516)
Parts Breakdown: not shown
A4
Access 4
Location: below the seat deck in front of the battery
Function: lift truck application input and output
Data: information received from the lift truck control
modules and the sensors
Adjustment: N/A
Diagrams: DIA-2515-005 (C-1) (511)
DIA-2515-015 (C-1) (521)
Parts Breakdown: 04.0-2515-005 (51) (887)
04.0-2615-052 (38) (913)
ALM HN
Horn
Location: on the overhead guard below the floorboard
M1.91-2515-201 Crown 2017 PF27779 Rev. 3/21
02 Rev. 3/21
78
--- Page 10 ---
COMPONENTRY
CMD KY SW
CMD KY SW Data: rocker switch, wired normally open
Adjustment: N/A
Key Switch Diagrams: DIA-2515-025 (C-2) (531)
Location: in the right side of the steer column Parts Breakdown: 04.0-2515-007 (73) (889)
Function: supplies power to the dash components,
ignition, and start signal to modules and power relays
Data: key-operated selector switch
Adjustment: N/A
Diagrams: DIA-2515-022 (C-1) (528)
Parts Breakdown: 06.0-2515-003 (30) (965)
06.0-2515-003 (31) (965)
CMD LGT WK/HD SW (hard
cabin)
Front Worklights or Front Worklights and Travel
Lighting Switch (Optional) (Hard Cabin)
Location: on the console
Function: turns on and off the front worklights or head-
lights
Data: rocker switch, wired normally open
Adjustment: N/A
Diagrams: DIA-2515-025 (B-1) (531)
DIA-2515-025 (C-1) (531)
Parts Breakdown: not shown
CMD LGT WK1 SW
Front Light Switch (Optional)
Location: on the accessory pod on the console
Function: turns on and off the front worklights
Data: wired in the open position, closed when the
switch is operated
Adjustment: N/A
Diagrams: DIA-2515-025 (C-1) (531)
Parts Breakdown: 04.0-2515-007 (72) (889)
CMD LGT WK3 SW
Back Workight Switch (Optional)
Location: on the accessory pod on the console
Function: turns on and off the back worklight
M1.91-2515-211 Crown 2017 PF27779 Rev. 3/21
02 Rev. 3/21
88
--- Page 11 ---
COMPONENTRY
FB CRK SNS
FB CRK SNS Data: +BV and B-NEG supplied to the pressure sensor,
B-NEG supplied to the temperature sensor
Crank Sensor Adjustment: N/A
Location: on the back of the engine on the flywheel Diagrams: DIA-2515-005 (B-1) (511)
housing DIA-2515-018 (D-3) (524)
Function: supplies the crankshaft speed input to A3 Parts Breakdown: 03.1-2515-242 (58) (825)
Data: magnetic proximity and inductive pickup
Adjustment: N/A
Diagrams: DIA-2515-004 (B-2) (510)
DIA-2515-012 (C-4) (518)
Parts Breakdown: 03.1-2515-360 (6) (835)
FB ENG TMP
Engine Coolant Temperature Sensor
Location: on the engine thermostat housing
Function: supplies the coolant temperature input to A3
Data: energized by +5 V Power Supply in A3
Adjustment: N/A
Diagrams: DIA-2515-004 (C-1) (510)
DIA-2515-012 (C-3) (518)
Parts Breakdown:
FB EOP SNS
Engine Oil Pressure Sensor
Location: on the right side of the timing gear cover
Function: supplies oil pressure input to A3
Data: energized by +5 V Power Supply in A3
Adjustment: N/A
Diagrams: DIA-2515-004 (C-1) (510)
DIA-2515-012 (C-3) (518)
Parts Breakdown: not shown
FB FLV SNS
Fuel Level Sensor
Location: above the air filter, connected to the fuel
line, after the fuel filter
Function: monitors the fuel temperature and the pres-
sure for the correct fuel level
M1.91-2515-221 Crown 2017 PF27779 Rev. 3/21
02 Rev. 3/21
98
--- Page 12 ---
COMPONENTRY
FU11
FU11 FU14
Dash Fuse Power Brake Fuse
Location: fuse box positions A1–B1 Location: fuse box A4–B4
Function: protects overcurrent on A1, ALM OP1, Function: protects overcurrent on ALM OP2,
CMD HN SW1, CMD KY SW, PRM1, and PRM2 CMD PBRK SW, and SV PBRK
Data: 5 A, 58 V Data: 10 A, 58 V
Adjustment: N/A Adjustment: N/A
Diagrams: DIA-2515-003 (A-2) (509) Diagrams: DIA-2515-003 (B-1) (509)
DIA-2515-007 (B-1) (513) DIA-2515-007 (B-2) (513)
Parts Breakdown: 04.0-2515-005 (37) (887) Parts Breakdown: 04.0-2515-005 (37) (887)
04.0-2615-052 (22) (913) 04.0-2615-052 (22) (913)
FU12 FU15
Engine Fuse A Access 4 High Side Drivers Fuse
Location: fuse box A2–B2 Location: fuse box A5–B5
Function: protects overcurrent on ALT, CR316, EPR, Function: protects overcurrent on A4, SV FF, and
FB HEGO SNS1, FB HEGO SNS2, K312, and SV PUF, ALM TVL, ALM HN
SV FLOC
Data: 15 A, 58 V
Data: 7.5 A, 58 V
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-2515-003 (B-1) (509)
Diagrams: DIA-2515-003 (B-1) (509) DIA-2515-007 (B-2) (513)
DIA-2515-007 (B-1) (513)
Parts Breakdown: 04.0-2515-005 (37) (887)
Parts Breakdown: 04.0-2515-005 (37) (887) 04.0-2615-052 (22) (913)
04.0-2615-052 (22) (913)
FU13
Engine Fuse B
Location: fuse box A3–B3
Function: protects overcurrent on ECU, K313, K314,
IGN COIL1–IGN COIL4, and M STRT
Data: 15 A, 58 V
Adjustment: N/A
Diagrams: DIA-2515-003 (B-1) (509)
DIA-2515-007 (B-1) (513)
Parts Breakdown: 04.0-2515-005 (37) (887)
04.0-2615-052 (22) (913)
M1.91-2515-231 Crown 2017 PF27779 Rev. 3/21
02 Rev. 3/21
108
--- Page 13 ---
COMPONENTRY
K53
K53 Parts Breakdown: not shown
Forward Floor Spotlight Driver Relay (Optional)
K91
Location: relay box Rear Work Light Driver
Function: switches BNEG for lights that turn on with Location: fuse box A9–B9 A10–B10
forward travel
Function: switches BNEG for LGT WK3
Data: N/A
Data: N/A
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-2515-039 (C-1)(545)
Diagrams: DIA-2515-007 (B-4) (513)
Parts Breakdown: not shown
Parts Breakdown: 04.0-2515-005 (60)(887)
K54 04.0-2615-052 (47)(913)
Rear Floor Spotlight Driver Relay (Optional)
K92
Location: relay box Drum Brake Alarm Driver
Function: switches BNEG for lights that turn on with Location: fuse box D9–F9 D10–F10
reverse travel
Function: switches +BV for ALM OP2
Data: N/A
Data: N/A
Adjustment: N/A
Adjustment: N/A
Diagrams: DIA-2515-039 (D-1)(545)
Diagrams: DIA-2515-005 (A-1) (511)
Parts Breakdown: not shown DIA-2515-007 (C-4) (513)
K60 (hard cabin) Parts Breakdown: 04.0-2515-005 (61)(887)
04.0-2615-052 (48)(913)
Defroster Timer Relay
Location: overhead guard
Function: switches +BV for timed period to HTR DFR
Data: N/A
Adjustment: N/A
Diagrams: DIA-2515-032 (C-3) (538)
Parts Breakdown:
K64 (soft cabin) (not shown)
Washer Motor Relay
Location: front center under the floorboard
Function: enables M WSH
Data: N/A
Adjustment: N/A
Diagrams: DIA-2515-034 (D-4)(540)
M1.91-2515-241 Crown 2017 PF27779 Rev. 3/21
02 Rev. 3/21
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--- Page 14 ---
COMPONENTRY
M WPR1 (hard cabin)
M WPR1 (hard cabin)
Front windshield wiper motor
Location: on the front windshield
Function: supplies power to the front windshield wiper
Data: 12 V–24 V
Adjustment: N/A
Diagrams: DIA-2515-032 (C-2) (538)
DIA-2515-034 (C-2) (540)
Parts Breakdown: 04.0-2615-100 (1) (917)
M WPR2 (hard cabin)
Rear windshield wiper motor