PLANNED MAINTENANCE

C-5 Planned Maintenance

Instructor’s Guide
®

Applies To:
C-5 Trucks
Prerequisites
Before attempting the skill check, the partici- ! CAUTION
pant must have successfully completed the Before performing any work, be sure to refer to
skill checks for the following modules: and follow all recommended safety precautions
o Shop Safety (DP00663) set out in the Crown Service and Parts Manual.
In addition, Crown recommends that all partici-
o Control of Hazardous Energy (DP00661) pants wear appropriate protective items, such as
o Crown Service and Parts Manuals safety glasses, work gloves, and steel-toed
(DP00634) shoes whenever performing maintenance work
o C-5 Component Identification (DP00854) on Crown equipment.

Module Explanation During the skill check, the participant must

demonstrate to you their ability to properly per-
This is a self-paced program. The participant form Planned Maintenance (PM) on a C-5 lift
must demonstrate to you their ability to prop- truck. This includes:
erly complete the skill check. All the directions
that will lead the participant through the course o Following all applicable safety procedures.
are contained within the module. Your job as Wearing the appropriate protective items.
the instructor is to: Chocking, locking-out, and tagging-out the
truck.
o Make sure safety procedures are followed
o Demonstrating how to inspect, lubricate
at all times.
and determine if adjustments or repairs/
o Provide an environment where the partici- replacements are required for all applicable
pant can complete the module. PM components.
o Provide necessary supplies, parts, special o Demonstrating how to complete the
tools, reference information, and equipment. Planned Maintenance and Inspection
o Be available for questions or assistance. Report.
o Provide constructive and supportive feed- o Cleaning up the truck and work area,
back if necessary. checking the truck for proper operation, and
o Watch the participant successfully perform returning the truck to normal service.
the skill check. Time
Skill Check The approximate completion time for the skill

!
check is 0.75 hours.
WARNING NOTE
Participants must be trained, authorized and cer- The time listed above is the approximate
tified by their employer for operation of the time required to complete the skill check
truck(s) being used for this module. Participants only. Additional time is required to read
or others around the participants can be seri- the module and any additional reference
ously injured or even killed if the truck(s) is/are material and conduct hands-on practice.
not used correctly. Since each participant learns at their own
pace, the total time required to complete
the module will vary with each participant.

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C-5 Planned Maintenance
Instructor’s Guide

Materials Required (for One Participant) • Telescoping Gauge, p/n 300089.

NOTE: Types and amounts of lubricants and types of • Common hand tools.
replacement parts required is dependant upon • C-5 Service and Parts Manual.
the interval of PM being performed. • Planned Maintenance Report Form for C-5 Series
(PF17737).
• All recommended safety equipment.
• A secure and safe work area with sufficient space and Implementing the Module
overhead clearance.
IMPORTANT!
• C-5 lift truck.
Inform the participant that they must contact you
• Tagout and lockout devices.
before attempting the hands on practice or skill
• Hardwood chocks. check portion of this module. You are to make sure
• Low pressure compressed air to blow off truck. the participant has read and understands the
• Grease guns loaded with cartridges containing the ENTIRE process/procedures, as well as all the
service manual recommended types of lubricants. safety precautions, before starting any work. You
• White Lithium Grease, p/n 363110. are to question the participant in order to determine
• Hydraulic oil, p/n 063001 (DTE 24) or 363504 (Anti- if the participant understands how to proceed in a
Wear). (Up to 37.8 liters or 10 gallons if changing oil.) safe manner. You must observe the participant dur-
ing the critical steps in the process/procedure to
• 10W-30 motor oil, p/n 063041 (Turf-Guard) or 363500
insure their safety as well as the safety of others.
(Crown). (Up to 7.6 liters or 8 quarts if changing oil.)
• Premium Chain & Cable Lube, p/n 363115 or 40 Beginning the Session
weight motor oil. o Familiarize yourself with all the materials and sup-
• Penetrating lubricant aerosol, p/n 363104. plies, the content and format of this module.
• Universal hydraulic & transmission fluid, p/n 363513. o Make sure all the materials needed are available
(11.4 liters or 12 quarts if changing oil.) before the instruction begins.
• Antifreeze/Coolant, p/n 363509. (Up to 10 liters or 11 o Introduce yourself and the purpose of the module.
quarts if draining/refilling system.)
o Ask the participant if they are trained, authorized and
• 80W-90 gear lube, p/n 363506. (Up to 5.7 liters or 6 certified by their employer for operation of the truck(s)
quarts if changing gear lube.) being used for this module. If they are not, do not per-
• Thread sealant, p/n 061004-023. mit them to operate the truck(s). As an alternative,
• Battery Cleaner, p/n 363124. you or another trained, authorized and certified partic-
• Battery Protector, p/n 363125. ipant may operate the truck for the participant during
• Shop towels. the practice and skill check portion of this module.
• Engine Air Filter element, p/n 142110. o Put the participant at ease by letting them know that
• Engine oil filter, p/n 141880. you will be available for any questions or assistance.
• Transmission oil filter, p/n 144925. o Review the module together, indicating the different
sections of the module.
• LPG fuel filter service kit, p/n 146943-001 (40 micron)
146943-002 (5 micron). o Let the participants know they can practice.
• Hydraulic return filter, p/n 142280. o Go over the location of the resource materials and
hand out all the printed materials.
• Hydraulic breather/dipstick assembly, p/n 139237.
o Tell the participant that they must notify you before
• Spark Plugs, p/n 141882 (quantity of four).
attempting the hands on practice or skill check por-
• Silicone Dielectric grease, p/n 063002-056.
tion of this module.
• Shop light or flashlight.
o Remind the participant that their safety and the safety
• Chain wear scale, p/n 106440. of others is of the utmost importance.
• Fork-wear calipers, p/n 107330.
• T-25 Tamper-Proof Torx screwdriver.

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 C-5 Planned Maintenance
Instructor’s Guide

Practice Session o Review the Planned Maintenance and Inspection

Report to make sure the form has been completed
o When the participant is ready to practice their skills,
properly.
they will notify you so you can provide them with the
materials and supplies needed for this module. o Be sure the participant has cleaned up the truck and
work area.
o Make sure the participant has read and understands
the ENTIRE module including all the safety precau- o Ask the participant to check all the functions of the
tions, before practicing. truck to be sure that the truck operates properly.
o Question the participant in order to determine if the Completion
participant understands how to proceed in a safe
manner.
o At the completion of the skill check, review participant
performance. Communicate all the correct skills they
o Inform the participant that you’re available during their performed and where they might improve.
practice to demonstrate the proper procedures if they
are unsure how to perform the procedures properly.
o Be supportive at all times.
o Observe the participant during the critical steps in the
o If at this time the participant requires more practice,
process/procedure to insure their safety as well as tell the participant to continue their practice.
the safety of others. o If at this time the participant has met all the criteria
listed on the skill check, sign the skill check and con-
Skill Check Session gratulate them on a job well done.
o The participant will notify you that they are ready for
Skill Check Assessment
their skill check. If there is more than one person
waiting for their skill check, have them sign in on a list The following inspections and questions are provided to
and take them in the order they signed in. assist you with the skill check. This assessment is not a
o Review the skill check criteria together to be sure the complete inspection of all components, just sample
participant understands what is expected of them in areas. Feel free to select different inspection areas and
order to successfully complete the skill check. questions for the skill check. If you choose not to
observe the participant perform the entire PM during the
o Remind the participant that he/she must follow any
skill check, ask the participant to notify you so you can
and all applicable safety precautions as specified in
check their progress before they reinstall the covers.
the Service and Parts Manual.
This will save time for you and the participant.
o Inform the participant that they may reference the
Service and Parts Manual or any other materials/ General Questions
information during the skill check.
What is the first step in performing a PM?
o Make sure the participant has read and understands
the ENTIRE module including all the safety precau- Expected answer: Conducting a thorough walk-around
tions, before performing the skill check. inspection of the truck.
o Question the participant in order to determine if the Choose seven to ten items from the list under PM walk-
participant understands how to proceed in a safe around inspection in the module, ask the participant to
manner. show you what to inspect for and how to properly note
o Provide the participant with the materials and sup- the inspection on the PM form.
plies needed for this module and instruct them to per-
Ask the participant to demonstrate checking fluid levels
form a PM on the truck you assigned to them.
prior to conducting a test drive. Refer to the training
o Inform the participant that you will be observing them module.
during their skill check to insure they have met all the
criteria listed on the skill check. You needn’t observe Ask the participant to demonstrate the Lift/Tilt interlock
the participant perform the entire skill check, but you system. Refer to the training module.
must observe the participant during the critical steps Ask the participant to demonstrate checking Inching
in the process/procedure to insure their safety as well pedal operation. Refer to the training module.
as the safety of others.
Why do you close the outlet valve on the LPG tank and
o When the participant has completed the PM, inspect
let the engine run out of fuel before servicing the truck?
several areas of the truck to be sure the planned
maintenance has been performed properly.

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C-5 Planned Maintenance
Instructor’s Guide

Expected answer: To relieve pressure in the fuel system.

How often should the tar (propylene residue) be drained
from the Electronic Pressure Regulator and Carburetor?
Expected answer: Every 500 hours of operation.
How often should the engine oil and filter be changed?
Expected answer: After the first 500 hours of operation
and then every 1,000 hours of operation.
What else should be done when the transmission fluid
and spin-on filter are changed?
Expected answer: Remove, clean, and reinstall the fluid
suction strainer.
Where are the drive axle check/fill and drain plugs
located and how often should the oil level be checked?
Expected answer: The check/fill plug is located on the
(inside) right hand side of the drive axle housing and the
drain plug is located in the bottom of the housing. Every
1,000 hours of operation.
What is the total number of grease fittings on the steer
axle assembly?
Expected answer: Six – three per side.
What is the total number of grease fittings for the mast
mount pivots?
Expected answer: Four – two per side.
Ask the participant to demonstrate checking chain
stretch.
Ask the participant to demonstrate checking fork wear.
Refer to the training module.

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Crown 2009 DP00866-ING Printed in U.S.A.