Crown Forklift GPC2000 Series Maintenance Manual 812528-006 – PDF DOWNLOAD
FILE DETAILS:
Crown Forklift GPC2000 Series Maintenance Manual 812528-006 – PDF DOWNLOAD
Language : English
Pages :194
Downloadable : Yes
File Type : PDF
TABLE OF CONTENTS:
Crown Forklift GPC2000 Series Maintenance Manual 812528-006 – PDF DOWNLOAD
GPC2000 1
TABLE OF CONTENT 5
TABLE OF CONTENT 2 6
TABLE OF CONTENT 3 7
TABLE OF CONTENT 4 8
TABLE OF CONTENT 5 9
TABLE OF CONTENT 6 10
SAFETY 13
Safety Symbols used in the Manual 13
General Maintenance and Repair Safety Notes 13
Maintenance and Repair 13
Before Leaving the Truck 14
Before Carrying out Work on the Truck 14
Before Operating the Truck 14
Warnings and Labels on the Truck 14
INTRODUCTION 17
General 17
Operating Instructions 17
Service Training 17
Ordering Spare Parts 17
Using the Manual 17
Model-Number 18
LUBRICATION AND ADJUSTMENT 21
Jacking up the Truck 21
Lifting the Truck with a Crane 21
Lifting the Truck with a second Truck 22
Towing the Truck 23
De-commissioning 24
Re-commissioning 24
Component Access 25
Models 27
Maintenance 28
Check and Maintenance Schedule 28
Daily or every 8 service hpurs (Part1) 28
Daily or every 8 service hpurs (Part2) 29
Monthly or every 100 service hours 30
Every 3 months or 250 service hours 32
Every 6 months or 500 service hours 32
Annually or every 1000 service hours 34
Every 2 years or 2000 service hours 34
Recommended Lubricants and Oils 37
Lubricants 37
Cold Store Trucks 37
Lubricant Type, Product, Manufacturer, Crown Part No, Type 37
Grease items and grease intervals 38
Torques 40
Screw grade marking Nut grade marking 40
Standard Screws and Nuts 41
Standard Screws and Nuts 41
HYDRAULICS 45
Hydraulic Symbols 45
Hydraulic System 49
Operation 49
Platform Lift 50
Fork High Lift 51
Platform Lift and Fork High Lift 52
Hydraulic Unit Removal 53
Replacing the Hydraulic Pump 54
Removal 54
Installation 54
Pump motor 54
Replacing the Hydraulic Filter 54
Replacing the Suction Filter 54
Replacing the Oil 54
Start-Up 54
Checking the Valve Settings 56
Checking the Non-Return Valve 56
Checking the Safety Valve 56
Adjusting the Safety Valve 56
DRIVE UNIT 61
General 61
Environmental Protection 61
Drive Wheel 61
Removal 61
Assembly 61
Drive Unit Removal 62
Drive Unit Assembly 62
Transmission 62
Transmission Removal 62
Transmission Assembly 62
Transmission Repairs 63
Disassembly 63
Assembly 63
Bevel Wheel Set Adjustment 64
Oil Change 66
Live Ring Bearing 66
Removal 66
Assembly 66
ELECTRICS 71
Electrics – General 71
Wire Colour Codes 71
Abbreviations 72
Switch Symbol Abbrevation List 72
Sundry Abbrevations 73
Other Abbrevations 74
Electrical Symbols 74
Electrical Components 75
Transmitter (POT, FS, RS) 75
Brake Switch (BRS) 75
Lift/Lower switches (RAS, LOS) 75
Lift limiting switch (LMS) 75
Horn Switch (HNS) 75
Key Switch (KYS) 75
Emergency Disconnect (EDS) 75
Fuses (FU) 75
Walk along switch (WAS) 76
GPC2020 76
GPC2040 77
Programmer 78
General 78
Connection 78
Key Description 78
Display 78
SCROLL DISPLAY 78
CHANGE SETTING 78
MORE INFO 79
PROGRAM 80
TEST 80
DIAGNOSTIC 80
Key Combinations 80
SPECIAL DIAGNOSTIC mode 80
SPECIAL PROGRAM mode 81
Deleting the Error History 81
Copying (Cloning) Controller Settings 81
Resetting to Original Settings 81
Programmer Self-Test 81
Traction Controller Removal / Installation 82
Removal 82
Installation 82
Controller Test 83
Traction Controller 1207 and 1214 Settings 84
Controller Settings 1207 (GPC2020) 84
Controller Settings 1214 (GPC2040-2040S) 84
Program Menu 85
Menu TEST 86
Diagnostic and Special Diagnostic Menu 87
Fault Recovery (including recovery from disable) 88
Test Procedure 89
Pulse Monitor Trip – Test (PMT) 89
Equipment 89
Test Procedure 89
PMT- Test Wiring Diagram 90
1207 and 1214 Traction Controllers 91
General 91
Operating Features 91
Functions 92
Key Switch 92
Autotest (Watchdog, internal and external) 92
Current Limit 92
Overvoltage 92
Overtemperature 92
Performance Reduction at Low Voltage 92
Error Detection 92
Error Listing 93
Error Reset 93
Maintenance 94
1207 Control Line Connections 95
Power Line Connections 95
1214 Control Line Connections 96
Power Line Connections 96
1207 Control Panel 97
Setting Potentiometers 97
Programmer Connection 97
Status LED 97
Diagnostics with Status LED 97
CONNECTION SIDE OF CONTROLLER 1214 98
Programmer connector 98
Status LED 98
LED Diagnostics 98
Status LED 99
No of Flashes, Display, Console Display, Explanation, Possible Cause 99
No of Flashes, Display, Console Display, Explanation, Possible Cause100
DACI-EL Steering Control System102
Electrical Connections102
Performance Connections102
Control Section Connections102
Steering Control System Error Codes102
DACI-EL Steering Control System Error Codes103
DACI-EL Steering Control System Error Codes (contd)106
Steering Control System Removal / Installation106
Removal106
Installation106
Distributor Boards108
General108
Driver Board Usage108
Board 804247-001109
Board 804247-002109
Board 804247-003109
Jumper Arrangement and Usage110
Jumper Settings111
Platform Lift and Combination 804824111
Electrical Steering Option112
LED Signalling Board 808191112
Board 808 191 Contact Arrangement112
Board 808 197114
Contactors115
Important115
Inspection115
Contacts115
Coils115
Springs115
GPC2020 Travel Contactor Repairs115
Disassembly115
Assembly116
GPC2040 and GPC2040S Travel Contactor Repairs117
Disassembly117
Assembly117
BRAKE121
Operational Description121
GPC 2020 Brake System121
GPC 2040 Brake System122
Removal123
Preparation123
Maintenance and Repairs123
Installation124
Air Gap Setting124
Brake Moment Setting125
Brake Test126
Braking Distance Setting126
GPC 2020 Standard 16 t126
Braking Distance with Max Load126
Braking Distance with Truck Unladen126
GPC 2040 Standard 20 t126
Braking Distance with Max Load126
Braking Distance with Truck Unladen126
GPC 2040 High Lift and Twin Lift 10 t126
Braking Distance with Max Load126
Braking Distance with Truck Unladen126
Testing the Load-Dependent Pressure Switch (GPC 2040 only)127
STEERING131
Steering Drive System131
Steering Drive Removal131
Repairing the Steering Drive131
Removing the Motor from the Transmission131
Replacing the Motor Bearings131
Repairing the Steering Transmission133
Tiller136
Tiller and Recuperating Spring Removal (All Models)136
Tiller and Recuperating Spring Assembly (All Models)137
Tiller Adjustment138
Forward Travel Setting for Mechanical Steering138
Forward Travel Setting for Electrical Steering139
Steering Chain140
Chain Tension Adjustment140
MAST143
Lifting Mechanism143
Lifting mechanism adjustment143
Lift Stop Setting144
Lift Chains145
General145
Inspection145
Cleaning145
Wear145
Freedom of Movement146
Chain Tension146
Chain Anchor and Pulleys146
Worn or Missing Plates146
Protruding or Turned Chain Pins146
Corrosion147
Chain Lateral Wear147
Uneven Chain Tension147
Misalignment of Lift Components147
Lift Chain Lubrication148
Fork Tine Test149
General149
Fork Identification149
Repairs149
Crack Inspection149
Fork Blade Warping150
Verticality Test150
Measuring the Fork Tip Width151
Fork Tine Height Difference151
Fork Stop151
Wear152
CYLINDER155
General158
Plunger Cylinders (single-acting)155
Single-Acting Cylinder157
Piston Cylinder (Double-Acting Cylinder)156
Double-Acting Cylinder157
General158
Cylinder Removal158
Replacing the Rod Seal158
Platform Lift Cylinder159
Free Lift Cylinder160
Free Lift Cylinder for Platform Lift and Combination161
DIAGRAMS165
Control Circuit 2020165
Driver Board 2020166
Traction Controller 2020167
Brake and BDI 2020168
Tiller and Pedestrian Function 2020169
Power Lead 2020170
Overview 2040171
Driver Board 2040172
Driver Board 2040/Platform Lift173
Traction Controller 2040174
Brake and Brake Switch 2040175
Lift/Lower and Limit Switch 2040176
Tiller: BDI and Pedestrian Function 2040177
Power Lead 2040178
Overview 2040S179
Steering Motor Controller 2040S180
Steering Sensor Encoder 2040S181
PCB Connection Lead 2040S182
Steering Feedback POT 2040S183
Backrest Control Cable 2040S184
Tiller Lead 2040S185
Tiller Head Cable 2040S186
Power Lead 2040S187
Power Lead 2040S Diagram188
HYDRAULIC SCHEMATIC191
2020/2040/2040S191
Platform Lift192
Fork Lift193
Platform/ Fork Lift194
IMAGES PREVIEW OF THE MANUAL:
S.M 5/24