Crown Forklift GPC2000 Series Maintenance Manual 812520-006

Description

Crown Forklift GPC2000 Series Maintenance Manual 812520-006 – PDF DOWNLOAD

FILE DETAILS:

Crown Forklift GPC2000 Series Maintenance Manual 812520-006 – PDF DOWNLOAD

Language : English
Pages :194
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Crown Forklift GPC2000 Series Maintenance Manual 812520-006 – PDF DOWNLOAD

MA – SAFETY PAGE SER-NR CUT REV
Safety Symbols used in the Manual 3 Rev1 04/00
General Maintenance and Repair Safety Notes 3
Maintenance and Repair 3 Rev1 04/00
Before Leaving the Truck 4
Before Carrying out Work on the Truck 4
Before Operating the Truck 4
Warnings and Labels on the Truck 4
ITD – INTRODUCTION PAGE SER-NR CUT REV
General 7
Operating Instructions 7
Service Training 7
Ordering Spare Parts 7
Using the Manual 7
Model-Number 8
M1 – LUBRICATION AND ADJUSTMENT PAGE SER-NR CUT REV
Jacking up the Truck 11
Lifting the Truck with a Crane 11
Towing the Truck 13
De-commissioning 14
Re-commissioning 14
Component Access 15
Models 17
Maintenance 18
Check and Maintenance Schedule 18
Recommended Lubricants and Oils 27
Lubricants 27
Cold Store Trucks 27
Grease items and grease intervals 28
Torques 30
M2 – HYDRAULICS PAGE SER-NR CUT REV
Hydraulic Symbols 35
Hydraulic System 39
Operation 39
GPC2020/2040/2040S 39
Platform Lift 40
Fork High Lift 41
Platform Lift and Fork High Lift 42
Hydraulic Unit Removal 43
Replacing the Hydraulic Pump 44
Removal 44
Installation 44
Replacing the Hydraulic Filter 44
Replacing the Suction Filter 44
Replacing the Oil 44
Start-Up 44
Checking the Valve Settings 46
Checking the Non-Return Valve 46
Checking the Safety Valve 46
Adjusting the Safety Valve 46
IV
TABLE OF CONTENT
MS-GPC2000-GB 04/02 • Rev A • Printed in Germany
M3 – DRIVE UNIT PAGE SER-NR CUT REV
Drive Unit 51
General 51
Environmental Protection 51
Drive Wheel 51
Removal 51
Assembly 51
Drive Unit Removal 52
Drive Unit Assembly 52
Transmission 52
Transmission Removal 52
Transmission Assembly 52
Transmission Repairs 53
Disassembly 53
Assembly 53
Bevel Wheel Set Adjustment 54
Oil Change 56
Live Ring Bearing 56
Removal 56
Assembly 56
M4 – ELECTRICS PAGE SER-NR CUT REV
Electrics – General 61
Wire Colour Codes 61
Abbreviations 62
Electrical Symbols 64
Electrical Components 65
Transmitter (POT, FS, RS) 65
Brake Switch (BRS) 65
Lift/Lower switches (RAS, LOS) 65
Lift limiting switch (LMS) 65
Horn Switch (HNS) 65
Key Switch (KYS) 65
Emergency Disconnect (EDS) 65
Fuses (FU) 65
Walk along switch (WAS) 66
GPC2020 66
GPC2040 67
Programmer 68
General 68
Connection 68
Key Description 68
Display 68
SCROLL DISPLAY 68
CHANGE SETTING 68
MORE INFO 69
PROGRAM 70
TEST 70
DIAGNOSTIC 70
Key Combinations 70
SPECIAL DIAGNOSTIC mode 70
SPECIAL PROGRAM mode 71
Deleting the Error History 71
Copying (Cloning) Controller Settings 71
Resetting to Original Settings 71
Programmer Self-Test 71
Traction Controller Removal / Installation 72
Removal 72
Installation 72
V
TABLE OF CONTENT
MS-GPC2000-GB • Rev A • Printed in Germany
M4 – ELECTRICS PAGE SER-NR CUT REV
Controller Test 73
Traction Controller 1207 and 1214 Settings 74
Fault Recovery (including recovery from disable) 78
Test Procedure 79
Pulse Monitor Trip – Test (PMT) 79
Equipment 79
Test Procedure 79
PMT- Test Wiring Diagram 80
1207 and 1214 Traction Controllers 81
General 81
Operating Features 81
Functions 82
Key Switch 82
Autotest (Watchdog, internal and external) 82
Current Limit 82
Overvoltage 82
Overtemperature 82
Performance Reduction at Low Voltage 82
Error Detection 82
Error Listing 83
Error Reset 83
Maintenance 84
1207 Control Line Connections 85
Power Line Connections 85
1214 Control Line Connections 86
Power Line Connections 86
1207 Control Panel 87
Setting Potentiometers 87
Programmer Connection 87
Status LED 87
Diagnostics with Status LED 87
Connection side of
Controller 1214 88
Programmer connector 88
Status LED 88
LED Diagnostics 88
Status LED 89
Status LED 90
DACI-EL Steering Control System 92
Electrical Connections 92
Performance Connections 92
Control Section Connections 92
Steering Control System Error Codes 92
Steering Control System Error Codes 93
Steering Control System Error Codes 94
Steering Control System Error Codes 95
Steering Control System Error Codes 96
Steering Control System Removal / Installation 96
Removal 96
Installation 96
Distributor Boards 98
General 98
Board 804247-001 99
Board 804247-002 99
Board 804247-003 99
Jumper Arrangement and Usage 100
Platform Lift and Combination 101
VI
TABLE OF CONTENT
MS-GPC2000-GB 04/02 • Rev A • Printed in Germany
M4 – ELECTRICS PAGE SER-NR CUT REV
Electrical Steering Option 102
Board 808 191 Contact Arrangement 102
Board 808 191 Contact Arrangment 103
Board 808 197 104
Contactors 105
Inspection 105
Contacts 105
Coils 105
Springs 105
GPC2020 Travel Contactor Repairs 105
Disassembly 105
Assembly 106
GPC2040 and GPC2040S Travel Contactor Repairs 107
Disassembly 107
Assembly 107
M-5 – BRAKE PAGE SER-NR CUT REV
Brake 111
Operational Description 111
GPC 2020 Brake System 111
GPC 2040 Brake System 112
Removal 113
Preparation 113
Maintenance and Repairs 113
Installation 114
Air Gap Setting 114
Brake Moment Setting 115
GPC 2020, Single Stage Brake 115
GPC 2040, Twin Stage Brake 115
GPC 2020 16 t, Brake Default Setting 115
GPC 2040 Standard 20 t, Brake Default Setting 115
GPC 2040 High Lift and Twin Lift 10 t, Brake Default Setting —————– 115
Brake Test 116
Braking Distance Setting 116
GPC 2020 Standard 16 t 116
Braking Distance with Max Load 116
Braking Distance with Truck Unladen 116
GPC 2040 Standard 20 t 116
Braking Distance with Max Load 116
Braking Distance with Truck Unladen 116
GPC 2040 High Lift and Twin Lift 10 t 116
Braking Distance with Max Load 116
Braking Distance with Truck Unladen 116
Testing the Load-Dependent Pressure Switch (GPC 2040 only) 117
M6 – STEERING PAGE SER-NR CUT REV
Steering Drive System 121
Steering Drive Removal 121
Repairing the Steering Drive 121
Removing the Motor from the Transmission 121
Replacing the Motor Bearings 121
Repairing the Steering Transmission 123
Steering 126
Tiller 126
Tiller and Recuperating Spring Removal
(All Models) 126
Tiller Adjustment 128
Forward Travel Setting for Mechanical Steering 128
VII
TABLE OF CONTENT
MS-GPC2000-GB • Rev A • Printed in Germany
M6 – STEERING PAGE SER-NR CUT REV
Forward Travel Setting for Electrical Steering 129
Steering Chain 130
Chain Tension Adjustment 130
M7 – LIFTING MECHANISM PAGE SER-NR CUT REV
Lifting Mechanism 133
Lifting mechanism adjustment 133
Lift Stop Setting 134
Lift Chains 135
General 135
Inspection 135
Cleaning 135
Wear 135
Freedom of Movement 136
Chain Tension 136
Chain Anchor and Pulleys 136
Worn or Missing Plates 136
Protruding or Turned Chain Pins 136
Corrosion 137
Chain Lateral Wear 137
Uneven Chain Tension 137
Misalignment of Lift Components 137
Lift Chain Lubrication 138
Fork Tine Test 139
General 139
Fork Identification 139
Repairs 139
Crack Inspection 139
Fork Blade Warping 140
Verticality Test 140
Measuring the Fork Tip Width 141
Fork Tine Height Difference 141
Fork Stop 141
Wear 142
M8 – CYLINDERS PAGE SER-NR CUT REV
Cylinders 145
General 145
Plunger Cylinders (single-acting) 145
Piston Cylinder (Double-Acting Cylinder) 146
Single-Acting Cylinder 147
Double-Acting Cylinder 147
Cylinder 148
General 148
Cylinder Removal 148
Replacing the Rod Seal 148
Platform Lift Cylinder 149
Free Lift Cylinder 150
Free Lift Cylinder for Platform Lift and Combination 151
DIA – ELECTRICAL DIAGRAMS PAGE SER-NR CUT REV
Control Circuit 2020 155
Driver Board 2020 156
Traction Controller 2020 157
Brake and BDI 2020 158
Tiller and Pedestrian Function 2020 159
Power Lead 2020 160
Overview 2040 161
VIII
TABLE OF CONTENT
MS-GPC2000-GB 04/02 • Rev A • Printed in Germany
DIA – ELECTRICAL DIAGRAMS PAGE SER-NR CUT REV
Driver Board 2040 162
Driver Board 2040/Platform Lift 163
Traction Controller 2040 164
Brake and Brake Switch 2040 165
Lift/Lower and Limit Switch 2040 166
Tiller: BDI and Pedestrian Function 2040 167
Power Lead 2040 168
Overview 2040S 169
Steering Motor Controller 2040S 170
Steering Sensor Encoder 2040S 171
PCB Connection Lead 2040S 172
Steering Feedback POT 2040S 173
Backrest Control Cable 2040S 174
Tiller Lead 2040S 175
Tiller Head Cable 2040S 176
Power Lead 2040S 177
Power Lead 2040S 178
HYD – HYDRAULIC SCHEMATIC PAGE SER-NR CUT REV
2020/2040/2040S 181
Platform Lift 182
Fork Lift 183
Platform/ Fork Lift 184

IMAGES PREVIEW OF THE MANUAL:

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