PDF Service Manual Crown FC 5700 Series Forklift - 7 MB
Maintain the high performance of your Crown FC 5700 Series forklift with this official service manual.
This comprehensive guide is written for trained technicians and contains all necessary information for servicing, troubleshooting, and repairing the forklift.
From electrical systems to hydraulics, every aspect of the machine is covered in detail.
This manual is essential for any facility that services Crown equipment.
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--- Page 1 ---
INTRODUCTION
Introduction
Introduction • Hydraulic systems
• Electrical systems
This manual is for qualified service technicians who
have been trained appropriately to perform trouble- For more information on service training, consult a
shooting and maintenance procedures on the lift truck. Crown dealer or visit
The manual contains information about maintenance,
troubleshooting, and replacement parts. Replacement parts
To ensure correct and fast service, always provide the
Operator instructions following information when contacting Crown for re-
This manual does not have operator instructions. Lift placement parts:
trucks are shipped with the operator instructions in tag • The part number
or booklet form. More copies can be ordered. The • The lift truck model number
booklets are used to ensure safe and trouble-free op- • The lift truck serial number
eration. For operator instructions, refer to Crown publi-
cations, “Operator Manual FC 5700 Series.” • The lift truck data number
Consult a Crown dealer or visit www.crown.com for:
Operator training • The newest service manuals
Crown has operator training programs that are avail- • The newest operator manuals
able through a Crown dealer. For more information on • Training
operator training, consult a Crown dealer or visit
• Lift truck capacities
Service training • Lift truck specifications
Service training is available for: Manual structure
This manual contains sections that have maintenance
• All Crown lift trucks
and replacement parts. The section descriptions are as
• Module systems follows:
Service and Parts Pages
Maintenance Replacement Parts
Section Description Section Description
MA Safety 1 Frame and Chassis Parts
M1 Inspection & Lubrication 2 Hydraulic Parts
M1.91 Componentry 3 Engine and Transaxle Parts
M2 Hydraulic 4 Electrical Parts
M3 Engine and Transaxle 5 Brake Parts
M4 Electrical 6 Steering Parts
M5 Brake 7 Lifting Mechanism Parts
M6 Steering 8 Cylinder Parts
M7 Lifting Mechanism 9 Attachment Parts
M8 Cylinders 10 Accessories
M9 Attachments 12 Labels and Decals
M10 Glossary
Crown 2022 PF28765 ITD-2057-001
41
--- Page 3 ---
SAFETY
Control of Hazardous Energy
Control of Hazardous Energy Lockout procedures with the battery installed
1. Disconnect the battery.
Control of Hazardous 2. See Figure 2. Install a lockout device (1) on the
battery connector.
Energy (Lockout/Tagout)
In the interest of safety and to ensure compliance with
OSHA Regulations for The Control of Hazardous En-
ergy (Lockout/Tagout), OSHA Standard 29 CFR 1
1910.147, Crown has developed guidelines for energy
control when performing service and maintenance on a
lift truck. Before performing any service or mainte-
nance, also review the appropriate sections in this ser-
vice manual.
Lockout/Tagout
Always lock out equipment with the appropriate lockout
device as the first means of energy control. Addition-
ally, use the appropriate tagout device. These devices
let all personnel know that the lift truck is not safe or Fig. 2 (36205)
available for operation. Do not remove the lockout/ Lockout procedures with the battery out of the lift
tagout device until the equipment is ready to be re- truck
turned to service. 1. See Figure 2. If possible, install a lockout
Technician Tips: A lockout/tagout kit (P/N 300037) is device (1) on the battery connector. Or, install a
available. tag with a cable tie on the battery connector to in-
form others that the lift truck is not available for op-
Tagout procedure eration.
1. Turn off the lift truck and remove the key.
Preparing the lift truck for maintenance
2. See Figure 1. To warn others that the lift truck is
being serviced, use a cable tie to apply a tag to the To perform maintenance on a lift truck safely, complete
steering wheel. the following procedures:
1. Follow the safety procedures. See SAFETY in the
service manual.
2. Wear the appropriate personal protective equip-
ment (PPE) required for the task.
3. Move the lift truck to a secure and well-ventilated
1 area with a level surface.
4. Apply the parking brake.
5. Fully lower the forks. Make sure that there is no
load on the forks.
6. Tilt the forks down so the weight of the carriage or
any attachments is not on the tilt cylinders.
7. Turn off the lift truck and remove the key.
8. Put the chocks against the wheels.
Fig. 1 (36204)
9. Disconnect the battery.
10. Lockout/tagout the lift truck.
Crown 2023 PF28766 MA-2057-100
9
--- Page 4 ---
SAFETY
Control of Hazardous Energy
8. See Figure 17. Put the jack stands (1) behind the 1. Follow all instructions in Preparing the lift truck for
steer axles (2) of the lift truck as shown. maintenance.
Technician Tips: If the mast cannot be lowered using
normal truck functions, lower the mast following the
procedure outlined under Manually lowering the mast
in this section.
2. Remove the forks.
3. Place the directional controls in neutral.
2 2 4. Turn on the lift truck.
5. See Figure 19. Raise the mast and position the
blocks under the second stage mast.
Technician Tips: If the mast cannot be raised using
1 normal truck functions, attach a lifting device to each
stage and raise each stage before blocking.
6. Secure the blocks to the mast channel using a
Fig. 17 (36219) clamp or ratchet tie down.
9. See Figure 18. Use a hydraulic jack to lift the lift 7. Lower the mast and position the appropriate length
truck one side at a time, and place the jack stands blocks under the third stage mast.
(1) under the steer axle (2) as shown.
8. Using a clamp or ratchet tie down, secure the
Technician Tips: Only one side is shown. Both sides blocks to the mast channel or the second stage
of the steer axle must be supported by jack stands. blocks.
9. Lower the fork carriage until the carriage rests on
the stops or place blocks under the carriage and
lower the carriage until weight rests on the blocks.
2
10. Turn off the lift truck.
1
Fig. 18 (36220)
Blocking the mast
See Figure 19.
Use 100 x 100 mm (4 x 4 in) or bigger hardwood or
composite blocks of appropriate length for supporting
the mast channels. Block both of the mast rails of each
stage to maintain truck stability.
Remove any carriage mounted accessory (such as the
carton clamp, slip sheet, or roll loader) except sideshift-
ers before blocking the masts. These accessories add
significant weight to the mast.
Crown 2023 PF28766 MA-2057-110
19
--- Page 5 ---
INSPECCIÓN Y LUBRICACIÓN
Lubricantes, aerosoles y suministros de servicio
Lubricantes, aerosoles y sumi- servicio recomendados. Utilice estos materiales para
las actividades de mantenimiento planificado de las
nistros de servicio carretillas de Crown.
Consulte las tablas contenidas en esta sección para
ver la lista de lubricantes, aerosoles y suministros de
Tabla de identificación de los lubricantes
Tipo de lubricante Número de Cantidad por paquete
referencia
363506-001 1 litro
A Gear lube 80W-90 (típico)
363506-012 (12) botes de 1 litro
363503-001 1 litro
AA Líquido para transmisiones automáticas (universal)
363503-012 (12) 1 litro
363513-001 1 litro
AAA Líquido universal hidráulico y para transmisiones
363513-012 (12) 1 litro
363514-001 1 litro
AAAA Aceite sintético para engranajes 75W-90
363514-012 (12) 1 litro
063002-034 Cartucho de 412 g
B Grasa (universal)
063002-045 (40) cartuchos de 412 g
063002-017 Cartucho de 412 g
BB Grasa (bajas temperaturas)
063002-046 (40) cartuchos de 412 g
363002-001 Cartucho de 396 g
BBB Grasa de calidad alimentaria (universal)
363002-030 (30) cartuchos de 396 g
063002-025 Cartucho de 412 g
BBBB Grasa de alta calidad (universal)
063002-026 18 litros
5B Grasa NLGI 00 063002-060 Bote de 453 g
C Aceite (SAE 40)
363500-001 1 litro
Aceite para motores (10W30)
363500-012 (12) 1 litro
CC
063041-001 1 litro
JD Turf Guard (10W30)
063041-012 (12) botes de 1 litro
363504-101 3,8 l
D (1) Aceite hidráulico
363504-106 (6) de 3,8 l
363505-101 3,8 l
DD Aceite hidráulico (bajas temperaturas)
363505-106 (6) de 3,8 l
DDD (2) Aceite hidráulico - Mobil DTE24 063001-021 3,8 l
4D(3) Aceite hidráulico - Mobil Univis HVI 13 063001-035 18 litros
NOTA: Las carretillas que trabajan en temperaturas bajo cero deben utilizar grasas y aceites hidráulicos para
bajas temperaturas.
(1) Servicio normal (a partir de 0,6 °C (a partir de 33 °F))
(2) Carretillas para cámaras frigoríficas estándar (-18 °C a 4 °C (0 °F a 40 °F))
(3) Carretillas para cámaras frigoríficas de baja temperatura (-40 °C a -12 °C (-40 °F a 10 °F)) No se deben
mezclar distintos tipos de aceite.
Crown 2011 PF25240-1 Rev. 8/15 M1.0-04.0-050
04 Rev. 8/15
45
--- Page 6 ---
INSPECTION AND LUBRICATION
Planned Maintenance
Lubrication and 20% standard hydraulic oil, P/N 063001021. Use
a rust preventive, P/N 078882, on the following compo-
The following information is intended to provide guide- nents to prevent corrosion:
lines for proper lubrication intervals as called out in the • Screws
Lubrication table. However, some operating conditions
require more frequent checks and lubrication than • Washers
listed. For example, applications with much dust or • Nuts
moisture require modification of the schedule to fit that • Roll pins
particular application. See the Lubrication and Adjust- • Retaining rings
ment section for the recommended lubricants listed in
the Lubrication Identification table and the Alternate Lubrication intervals must be changed to a frequency
Lubricants and Fluids table. that minimizes corrosion and wear on moving shafts
and parts.
Freezer condition lift trucks require a mixture of low
temperature hydraulic oil, P/N 363505101 (1 gal).,
blended with standard hydraulic oil, P/N 063001021.
100% low temperature oil is too thin for most cold stor-
age operations and therefore could shorten the life of
cylinder packings and pumps if used in higher ambient
temperatures.
Technician Tips: Lift trucks equipped with velocity
fuses may experience staging issues if an insufficient
mix of low temperature oil has been used.
1
2
3
Fig. 3 (35720)
1 Hydraulic oil, P/N 063001-001 (100%)
2 50 / 50 Blend of low-temp hydraulic oil, P/N 063001-006
(50%) and standard hydraulic oil, P/N 063001-021 (50%)
3 80 / 20 Blend of low-temp, P/N 063001-006 (80%) and stan-
dard hydraulic oil, P/N 063001-021 (20%)
For lift truck applications operating continually in tem-
peratures at or above 4 °C (40 °F), use 100% standard
hydraulic oil, P/N 063001-001.
For lift truck applications primarily operating in a cooler
environment with intermittent freezer entry, use a 50/50
blend of low temperature, P/N 063001-006, and stan-
dard hydraulic oil, P/N 063001-021. For lift trucks oper-
ating continuously at temperatures of -12 °C (10 °F) or
below, use an 80% low temperature, P/N 063001-006,
Crown 2023 PF28767 M1.0-2057-005
59
--- Page 7 ---
INSPECTION AND LUBRICATION
Planned Maintenance
Inspection
180 d
Index Component
500 h
I-1 Worklights Check
I-2 Tail lights Check
I-3 Horn switch Check
I-4 Horn Check
I-5 Travel alarm Check
Strobe (not shown) Check
Impact sensor (not shown) Check
Floor spotlights and warning lights (not shown) Check
Crown 2023 PF28767 M1.0-2057-015
69
--- Page 8 ---
INSPECTION AND LUBRICATION
Planned Maintenance
Inspection
180 d
Index Component
500 h
I-1 Load backrest Check
I-2 Carriage Check
I-3 Forks Check
I-4 Fork latches Check
I-5 Sideshifter (slide, cylinder, and mounting hardware) Check
I-6 Mast pivot bearings and installation screws Check
Mast hydraulic lines, hoses, and fittings (not shown) Check
Mast cable and wiring (not shown) Check
Crown 2023 PF28767 M1.0-2057-025
79
--- Page 9 ---
COMPONENTRY
Componentry
ALM1 Adjustment: See the ELECTRICAL SYSTEM /
Switches section
Status Alarm (Not Shown)
Parts Manual Location: ELECTRICAL PARTS / Lever
Location: Internal to Access 1 - Control
Purpose: Alerts the operator of improper operator se-
quence or when the display logs an event. The alarm
sounds briefly when the lift truck is turned on
Data: Controlled by Access 1. To view ALM1 status,
see the ELECTRICAL SYSTEM / Access 1 2 3® Menu
- Analyzer Menus section. To test ALM1, see the
ELECTRICAL SYSTEM / Access 1 2 3® Menus / Ana-
lyzer Menus section
Adjustment: Not applicable
Parts Manual Location: ELECTRICAL PARTS / Com-
ponents - Electrical - Power Unit
ALM2
Travel Alarm (Optional)
Location: Under the floorboard, mounted on the right
side of power unit under the traction motor
Purpose: Provides an audible warning of lift truck
travel
Data: Controlled by Access 3™. Access 3™ provides
battery positive and negative to ALM2. To view
Access 3™ output to ALM2, see the ELECTRICAL
SYSTEM / Access 1 2 3® Menus / Analyzer Menus
section. To test Access 3™ output to ALM2, see the
ELECTRICAL SYSTEM / Access 1 2 3® Menus / Ana-
lyzer Menus section
Adjustment: Can be disabled or set to sound during
forward travel, reverse travel, or all travel. To view the
ALM2 setting, see the ELECTRICAL SYSTEM /
Access 1 2 3® Menu - Features Menus section. To
change the ALM2 setting, see the ELECTRICAL SYS-
TEM / Access 1 2 3® Menus / Features Menus section
Parts Manual Location: ELECTRICAL PARTS / Com-
ponents - Electrical - Power Unit
AXS3
Third Accessory Fifth Function Switch (Optional)
(Manual Valve) (Not Shown)
Location: Tilt lever
Purpose: Indicates that the operator had requested
the third accessory fifth function
Data: This momentary switch is normally wired open.
Provides positive to the fifth function solenoid coil, SVX
M1.91-2057-004 Crown 2023 PF28769
80
--- Page 10 ---
COMPONENTRY
Componentry
FAN1 Parts Manual Location: Not applicable
Access 3™ Cooling FAN5
Location: The controller panel, in the back of the lift Traction Motor Floorboard Fan
truck
Location: Under the floorboard
Purpose: Cools Access 3™ module
Purpose: Cools traction motor (M1)
Data: Controlled by Access 3™. FAN1 receives bat-
tery positive and negative from Access 3™ when Data: Not applicable
Access 3™ temperature is greater than 45 °C (113 °F). Adjustment: Not applicable
Voltage is removed when Access 3™ temperature is
less than 40 °C (104 °F). To view Access 3™ output to Parts Manual Location: ELECTRICAL PARTS / Com-
FAN1, see the ELECTRICAL SYSTEM / ponents - Electrical - Power Unit
Access 1 2 3® Menus / Analyzer Menus section. To
test Access 3™ output to FAN1, see the ELECTRICAL FAN6
SYSTEM / Access 1 2 3® Menus / Analyzer Menus Traction Motor Floorboard Fan
section
Location: Under the floorboard
Adjustment: Not applicable
Purpose: Cools traction motor (M2)
Parts Manual Location: ELECTRICAL PARTS / Panel
- Controller Data: Not applicable
Adjustment: Not applicable
FAN2
Parts Manual Location: ELECTRICAL PARTS / Com-
Access 2 Cooling ponents - Electrical - Power Unit
Location: The controller panel, in the back of the lift
truck FB IMP SNS
Purpose: Cools Access 2 module Impact Sensor (Optional) (Not Shown)
Data: Controlled by Access 2. FAN1 receives battery Location: Mounted to the power unit behind the left
positive and negative from Access 2 when Access 2 drive tire and under the drive unit
temperature is greater than 45 °C (113 °F). Voltage is Purpose: Provides lift truck impact information to the
removed when Access 2 temperature is less than InfoLink® module
40 °C (104 °F). To view Access 2 output to FAN1, see
the ELECTRICAL SYSTEM / Access 1 2 3® Menus / Data: Receives positive 5 V and negative voltage from
Analyzer Menus section. To test Access 2 output to the InfoLink® module
FAN1, see the ELECTRICAL SYSTEM / Adjustment: Not applicable
Access 1 2 3® Menus / Analyzer Menus section
Parts Manual Location: ACCESSORIES / InfoLink®
Adjustment: Not applicable
Parts Manual Location: ELECTRICAL PARTS / Panel FB PROX SNS
- Controller
Proximity Sensor (Optional) (Not Shown)
FAN4 Location: On the side of the InfoLink® module
Operator Fan Purpose: Reads the ID card and logs in the operator
to the InfoLink® module
Location: On the overhead guard post
Data: 5 V
Purpose: Cools the operator.
Adjustment: Not applicable
Data: FAN4 receives battery positive from the battery
when the fan switch FNS is closed. Battery positive is Parts Manual Location: Not applicable
supplied when the battery is connected
Adjustment: Not applicable
M1.91-2057-014 Crown 2023 PF28769
90
--- Page 11 ---
COMPONENTRY
Componentry
HGTSW1 height specified by the customer. HGTS3 provides
positive input signal to Access 2 when the switch is
Height Switch 1 closed. To view the input signal, see the ELECTRICAL
SYSTEM / Access 1 2 3® Menus / Analyzer Menus
Location: On the top of the outer (first stage) mast, on
section
the left side for TT and TL masts. For TF and Quad
masts, the switch is on the right side Adjustment: Not applicable
Purpose: Provides the height input to Access 1 and Parts Manual Location: Not applicable
Access 3™ for speed and brake limits when the forks
are above freelift. HGTSW1 also provides input for the
lift and tilt interlock when raising and tilting the mast
more than 2 degrees when the forks are above free-lift
Data: This momentary contact switch is connected nor-
mally open but held closed when the mast is below
staging. CLS provides the positive input signal to
Access 1 and Access 3™ when the switch is closed.
To view the input signal, see the ELECTRICAL SYS-
TEM / Access 1 2 3® Menus / Analyzer Menus section
Adjustment: Not applicable
Parts Manual Location: LIFTING MECHANISIM
PARTS / Mast - TL, LIFTING MECHANISIM PARTS /
Mast - Trucker’s, LIFTING MECHANISIM PARTS /
Mast - TF, LIFTING MECHANISIM PARTS / Mast - TT,
LIFTING MECHANISIM PARTS / Mast - Quad
HGTSW2
Height Switch 2 (Not Shown)
Location: On the mast
Purpose: Additional speed and braking limit or raise
cutout switch per customer specifications
Data: This momentary contact switch is connected nor-
mally open and held closed when the mast is below the
height specified by the customer. HGTS2 provides a
positive input signal to Access 1 when the switch is
closed. To view the input signal, see the ELECTRICAL
SYSTEM / Access 1 2 3® Menus / Analyzer Menus
section
Adjustment: Not applicable
Parts Manual Location: Not applicable
HGTSW3
Height Switch 3 (Not Shown)
Location: On the mast
Purpose: Additional speed and braking limit or raise
cutout switch per customer specifications
Data: This momentary contact switch is connected nor-
mally open and held closed when the mast is below the
M1.91-2057-024 Crown 2023 PF28769
100
--- Page 12 ---
COMPONENTRY
Componentry
Lowering Control Manifold (Manual records the event code. See Access 3™ current output
to M2, M2 temperature, and M2 rpm, see the ELEC-
Valve) TRICAL SYSTEM / Access 1 2 3® Menus / Analyzer
Location: On the lower part of the outer (first stage) Menus section
mast Adjustment: Not applicable
Purpose: Controls the maximum lowering speed re- Parts Manual Location: DRIVE UNIT PARTS / Motor
gardless of the load weight - Traction
Data: Not applicable
M3
Adjustment: Not applicable
Hydraulic Motor
Parts Manual Location: HYDRAULIC PARTS / Mani-
fold - Lowering Control Location: Under the battery
Purpose: Provides the operating force for the lift pump
M1
Data: Access 2 provides speed control in relation to
Right Traction Motor the operator input (POT1 and POT4). Access 2 pro-
Location: Under the floorboard, on the right side vides 3phase AC voltage to M3 to increase the pump
speed to the commanded speed, then holds M3 at that
Purpose: Provides the operating force for travel and speed through input from ECR3 and ECR4 until the
regenerative braking command or conditions change. Access 2 senses over
Data: Access 3™ controls the speed and direction of temperature condition through TS3 (internal to the mo-
M1 in relation to the operator input (POT2, POT3, FS, tor) and records the event code. See Access 2 current
and RS). Access 3™ provides 3phase AC voltage to output to M3, M3 temperature, and M3 rpm, see the
M1 to accelerate or decelerate the lift truck to the com- ELECTRICAL SYSTEM / Access 1 2 3® Menus / Ana-
manded speed. Access 3™ then holds M1 at that lyzer Menus section. To test output from Access 2 to
speed through input from ECR1 until the command or M3, see the ELECTRICAL SYSTEM / Access 1 2 3®
conditions change. Access 3™ senses M1 over tem- Menus / Analyzer Menus section
perature conditions through TS1 (internal to motor) and Adjustment: Not applicable
records the event code. To view the Access 3™ cur-
rent output to M1, M1 temperature, and M1 rpm, see Parts Manual Location: HYDRAULIC PARTS / Motor
the ELECTRICAL SYSTEM / Access 1 2 3® Menus / - Pump
Analyzer Menus section
Adjustment: Not applicable
Parts Manual Location: DRIVE UNIT PARTS / Motor
- Traction
M2
Left Traction Motor
Location: Under the floorboard, on the right side
Purpose: Provides the operating force for travel and
regenerative braking
Data: Access 3™ controls the speed and direction of
M2 in relation to the operator input (POT2, POT3, FS,
and RS). Access 3™ provides 3phase AC voltage to
M2 to accelerate or decelerate the lift truck to the com-
manded speed. Access 3™ then holds M2 at that
speed through input from ECR2 until the command or
conditions change. Access 3™ senses M2 over tem-
perature conditions through TS2 (internal to motor) and
M1.91-2057-034 Crown 2023 PF28769
110
--- Page 13 ---
COMPONENTRY
Componentry
POT4 Purpose: Provides the operator first accessory com-