Crown Forklift GPC 3000 SERIES MAINTENANCE MANUAL PDF

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Crown Forklift GPC 3000 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift GPC 3000 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

Language : English
Pages :260
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift GPC 3000 SERIES MAINTENANCE MANUAL – PDF DOWNLOAD

GPC 3000 SERIES 1
Safety page serial no cut Rev 5
Introduction page serial no cut Rev 5
Lubrication & Adjustment page serial no cut Rev 5
Hydraulic System page serial no cut Rev 5
Drive Unit page serial no cut Rev 6
Electrical System page serial no cut Rev 6
Brake System page serial no cut Rev 8
Steering page serial no cut Rev 8
Lifting Mechanism page serial no cut Rev 9
Cylinders page serial no cut Rev 9
Schematic Diagrams page serial no cut Rev 10
Hydraulic Schematic page serial no cut Rev 11
Safety 13
Symbols and Indicators 17
Safety Symbols 17
General Symbols 17
Fork direction 17
General Text Indicators 17
General Safety Instructions 18
Maintenance and Repair Instructions 18
Maintenance and Repair 18
Before Parking the Truck 18
Before Working on the Truck 18
Before Starting the Truck 18
Warning and Instruction Decals on the Truck 18
Introduction 21
General 23
Service training 23
Replacement Parts 23
Subsequent Attachments and Modifications 23
Using the Manual 23
Contact Address 23
Models 24
Lubrication & Adjustment 25
Lifting and Jacking 27
Lifting the Truck 27
Lifting the truck with a crane 27
Lifting the truck with a forklift truck 28
Towing the truck 28
Towing the truck 28
Jacking up the truck 29
Jacking up the truck 29
Taking the Truck out of Service 30
Testing Re-Commissioned Trucks 30
Restoring the Truck to Service 30
Recommended Lubricants and Accessories 31
Cold Store Trucks 31
Routine Maintenance 33
GPC 3020/40/60 Inspection and Lubrication Points 37
GPC 3045 Inspection and Lubrication Points 39
GPC 3055 Inspection and Lubrication Points 41
Torques 43
Standard Torques 43
Hydraulic System 45
General 47
Hydraulic Lines and Ports 47
Bleeding the hydraulic system 47
Drift Test 47
Oil Change 47
Capacity 47
Relief Valves 48
Replacing relief valves 49
Testing and adjusting the relief valves 49
RV1 test 49
RV2 test 49
Adjusting RV1/RV2 49
Hydraulic Unit 50
Hydraulic unit removal 50
Hydraulic unit assembly 50
12 kW hydraulic unit disassembly 50
Dismantling 50
Assembly 51
Start Up Procedure 51
22 kW hydraulic unit disassembly 53
Dismantling 53
Bleeding and Flushing the System 56
Before flushing and bleeding the system 56
Bleeding 56
Flushing 56
Drift Test 56
Drive Unit 59
Changing the Transmission Oil 61
Components 63
Replacing the shaft seal of the driven shaft 64
Special Tools Required 65
Preparation 65
Shaft Seal Removal 65
Removing the driven shaft 65
Driven shaft assembly 65
Adjusting the driven shaft friction torque 65
Drive Wheel and Wheel Bolts 67
Drive Wheel Disassembly 67
Drive Wheel Assembly 67
Replacing the Wheel Bolts 67
Replacing the Drive Unit 68
Special Tools Required 68
Removal 68
Assembly 68
Drive Transmission Unit 69
Repairing the Drive Transmission Unit 70
Preparation 70
Dismantling 70
Driven shaft removal 70
Bevel gear and bevel pinion removal 70
Assembly 71
Bevel pinion and drive pinion 71
Bevel gear 72
Electrical System 75
General 77
Wire colour code 77
Contact Symbol Abbreviations 78
Electrical Symbols 80
Components 82
GPC 3020/40/60 without Platform Lift 82
GPC 3040/60 with Platform Lift 85
GPC 3045 with Platform Lift 89
GPC 3055 92
Operator Menu 95
Operator Menu 96
Service Menu 97
Analyzer 97
Analyzer 98
Access 2 Input100
Access 3 Input101
Access 5 Input102
Test Output103
Calibration104
Calibration105
Features106
Features107
Features108
Features109
Hours110
Events111
Performance112
Performance113
Performance114
Performance115
Performance116
Utilities117
Parameter Setting118
Parameter Setting for the GPC 3020118
Parameter Setting for all Trucks except the GPC 3020119
Control Modules122
General122
Power Fuses122
Servicing and Replacing the Control Modules123
Discharging the Capacitors123
Servicing the Control Modules123
Replacing Control Modules123
Removal123
Assembly123
Event Codes124
Access 2124
Event Codes128
Access 3128
Event Codes136
Access 5136
Drive Motor144
Drive Motor Disassembly144
Drive Motor Assembly144
Repairing the Drive Motor145
Preparation145
Dismantling the Rotor Assembly145
Assembling the Rotor Assembly145
Final task:145
Steer Motor146
Special Tools Required147
Steer Motor Disassembly147
Steer Motor Assembly147
Repairing the Steer Motor147
Preparation147
Steer Motor Disassembly147
Steer Motor Assembly147
Final task:147
Pump Motor148
General Maintenance Instructions148
Maintenance Instructions148
12 kW Pump Motor148
Brushes148
Armature149
22 kW Pump Motor149
Brushes149
Armature149
Battery150
General150
Charging the Battery150
Replacing the Battery150
Contactors151
Inspection151
Contacts151
Coils151
Springs151
Servicing152
Dismantling152
Assembly152
Controller Safety Test (PMT)153
General153
Required tools153
Carrying out the PMT153
General153
Testing Access 3153
General153
Performing the test153
Testing Access 5154
General154
Brake System155
Electromechanical Brake157
General157
Servicing the Brake157
Measuring the air gap157
Replacing the Brake158
Installing a wear part kit158
Remove and disassemble the brake158
Replacing wear parts158
Brake re-assembly159
Replacing the brake in full160
Removal160
Assembly160
Steering163
Steering Assembly165
Steering Assembly Components166
Steering Assembly Removal166
Steering Assembly Installation166
Final tasks:166
Repairing the Steering Transmission167
Preparation167
Dismantling167
Assembly167
Final tasks:168
Lifting Mechanism169
GPC 3020/40/60 Fork Height171
General171
Adjusting the Height of the Lowered Forks171
Lift Chains173
Inspection173
Cleaning Methods173
Wear173
Freedom of Movement of Chain Links175
Chain tension175
Chain Anchor and Pulleys176
Worn Connection Plates176
Protruding or Turned Chain Pins176
Corrosion177
Side wear177
Uneven chain tension177
Misaligned Lift Components177
Lift Chain Lubrication178
General178
Lubrication Intervals179
Lubrication179
Separating Lift Chains180
Tools and Equipment Required180
Forks181
General181
Repairs181
Checking the Forks181
Crack Inspection181
Cylinders183
General185
Safety185
For your personal protection185
Hydraulic System Repair Instructions185
Tools186
Producing extractors186
Protective mechanisms186
Gasket Assembly187
Old Gasket Removal187
Large Gasket Assembly187
Tools required187
Assembly187
Small Gasket Assembly188
Tools required188
Assembly188
Rod Seal Assembly, Sealing Lip First189
Servicing190
General190
Cylinder Disassembly190
Replacing the Rod Seals190
Schematic Diagrams193
Overview195
With Key Switch and Keypad196
TCM – Combi AC1 Power Side197
TCM – Combi AC1 Logic Side198
SCM – EPS AC0 Logic Side199
Interface #1 Tiller200
Interface #2 Backrest201
GPC3045, 3055 Connections203
Switch Connection204
Handle Circuit206
Display with Options207
CAN Connection209
Power Cables GPC 3000210
Harness, Walk Beside Switch211
GPC3055211
Tables for Fig 818598_2G_1 (see page 199)212
Connector housing212
Contact pins212
Wire connections212
Beside Switch Assy213
GPC3055 (no PPC)213
Connector housing213
CAN Interface Bridge214
GPC3055214
Connector housing214
Lift / Lower Scissors Harness215
GPC3040 / 3060, GPC3045215
Connector housing215
Scissors RAS – LOS Assy216
GPC3055 (no PPC)216
Connector housing216
Walk Beside Switch Harness F/C217
Tables for Fig 820541_2B_1 (see page 205)218
Connector housing218
Contact pins218
Wire connections218
Microswitch Assy219
Connector housing219
Contact pins219
Horn Harness220
Connector housing220
Contact pins220
Horn Switch Assembly221
SAS Switch Assembly222
Main Harness GPC 3000223
Tables for Fig 818240-1_2Q (see page 211)224
Connector housing224
Cable lugs224
Contact pins225
Wire connections225
X10 Handle Harness227
Connector housing227
Contact pins227
Wire connections228
Display Harness GPC 3000229
Tables for Fig 818597_2L_1 (see page 217)230
Contact pins230
Connector housing230
Wire connections230
Adapter ZAPI Console231
Contact pins231
Connector housing231
BRK Switch Assembly232
X10 – Handle232
Contact pins232
GPC 3000 Standard233
CAN-Tiller Harness Assembly233
Contact pins233
Connector housing233
GPC Standard 3000234
Steer Sensor Assembly234
Contact pins234
Connector housing234
Walk Beside Switch Assy235
Contact pins235
Connector housing235
Platform Lift Harness236
Contact pins237
Connector housing237
Wire connections237
Backrest Harness #2 Platform Lift238
Contact pins238
Connector housing238
Straight Ahead Sensor Assy239
Contact pins239
Connector housing239
CAN Interface Bridge240
Contact pins240
Connector housing240
Lift Lower Scissors Harness GPC 3000241
Contact pins241
Connector housing241
LMS Harness Scissors Lift242
Contact pins242
Scissors RAS – LOS Assy GPC 3000243
Connector housing243
Platform Lift Fork Switch Assembly RAS / LOS 2-5244
Connector housing244
Backrest Harness #2 Platform / Forks245
Contact pins245
Connector housing245
Battery Latch Switch (BLS) Assy246
Contact pins246
Connector housing246
Adapter Key Switch247
Contact pins247
Walk Beside Switch Harness F/C248
Contact pins248
Connector housing248
Wire connections249
Heater Assembly250
Order number 820639-001250
Order number 820639-002250
Order Numbers 820639-001 & 820639-002250
Connection Cable Alarm251
Contact pins251
Connector housing251
Connection Cable DC / DC Converter252
Contact pins252
Connector housing252
DC / DC Converter253
Contact pins253
Connector housing253
Hydraulic Schematic255
GPC 3020257
GPC 3040/3045/3060 without Platform, GPC 3055258
GPC 3040/3045/3060 with Platform259

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