Crown GPC2000 Series Lift Truck Parts Catalogue Manual Instant Download

Parts Manual Ersatzteilhandbuch Manual de pi ces detach s GPC 2000 Series U1-Parts.p65 1 02.02.01, 09:42

TABLE OF CONTENT Printed in Germany

TABLE OF CONTENT Table of Content MA SAFETY Safety Symbols used in the Manual....................................... M/P-MA-0000-001 PAGE SERIAL NR. CUT REV. Rev.1 4/00 ITD INTRODUCTION General .................................................................................. P-ITD-6620-001 Page Numbers ....................................................................... M/P-ITD-6620-002 PAGE SERIAL NR. CUT REV. Rev.1 11/00 P-1.1 LUBRICATION Lubrication Type ..................................................................... P-1.1-6620-002 PAGE SERIAL NR. CUT REV. DIA ELECTRICAL DIAGRAMS Diagrams 2020....................................................................... M/P-DIA-6620-001 Diagrams 2040....................................................................... M/P-DIA-6620-025 Diagrams 2040S .................................................................... M/P-DIA-6620-050 PAGE SERIAL NR. CUT REV. Rev.1 01/01 Rev.1 01/01 M/P HYDRAUKIC Hydraulic Schematic .............................................................. M/P-2.0-6620-001 PAGE SERIAL NR. CUT REV. SECTION 1 COVERS Caster Wheel ......................................................................... P-1.5-6620-001 Load Wheel ............................................................................ P-1.5-6620-025 Covers ................................................................................... P-1.6-6620-001 PAGE SERIAL NR. CUT REV. Rev.2 01/01 Rev.1 01/01 Rev.2 01/01 SECTION 2 HYDRAULIC PARTS Tube/Hose Layout .................................................................. P-2.1-6620-001 Pumpen Motor and Pump ...................................................... P-2.13-6620-001 PAGE SERIAL NR. CUT REV. Rev.2 01/01 SECTION 3 DRIVE UNIT Drive Unit............................................................................... P-3.0-6620-001 Gearbox ................................................................................. P-3.1-6620-001 Drive Motor ............................................................................ P-3.2-6620-001 Knuckle ................................................................................. P-3.3-6620-001 PAGE SERIAL NR. CUT REV. Rev.2 01/01 Rev.1 01/01 Rev.3 06/01 Rev.2 01/01 SECTION 4 ELECTRICAL Control Panel ......................................................................... P-4.1-6620-001 Steering Controller ................................................................. P-4.2-6620-001 Drive Board............................................................................ P-4.3-6620-001 Contactor ............................................................................... P-4.4-6620-001 Quick Pic............................................................................... P-4.6-6620-001 Accelerator Switch ................................................................. P-4.6-6620-025 Lift/Lower and Horn ................................................................ P-4.6-6620-050 Control Handle ....................................................................... P-4.6-6620-075 Handle ................................................................................... P-4.6-6620-077 Control Handle (Cap) .............................................................. P-4.6-6620-079 Foot Brake/Walk Along 2020/2040 ......................................... P-4.6-6620-100 Walk Along and Lift/Lower 2040S ........................................... P-4.6-6620-125 Platform ................................................................................. P-4.6-6620-150 PAGE SERIAL NR. CUT REV. Rev.2 01/01 Rev.2 01/01 Rev.2 01/01 Rev.2 01/01 Rev.1 01/01 Printed in Germany REV. 2 06/01 P-IDX-6620-001

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TABLE OF CONTENT Battery Connector/Emergency Disconnect............................. P-4.7-6620-001 Dash Board ............................................................................ P-4.9-6620-001 Steer Indicator ....................................................................... P-4.9-6620-025 Rev.1 2/97 Rev.2 01/01 SECTION 5 BRAKE Brake 2020 ............................................................................ P-5.6-6620-001 Brake 2040/2040S ................................................................. P-5.6-6620-025 PAGE SERIAL NR. CUT REV. Rev.1 2/97 Rev.2 01/01 SECTION 6 STEERING Steering ................................................................................. P-6.2-6620-001 Steering Motor ....................................................................... P-6.2-6620-025 Steering ................................................................................. P-6.4-6620-001 Steering Column .................................................................... P-6.7-6620-001 PAGE SERIAL NR. CUT REV. Rev.1 2/97 SECTION 7 MAST/LIFT STRUCTURE Platform Lift ........................................................................... P-7.1-6620-001 Fork Lift ................................................................................. P-7.1-6620-025 Fork Carriage ......................................................................... P-7.7-6620-001 Lift Structure .......................................................................... P-7.8-6620-001 Load Backrest........................................................................ P-7.10-6620-001 Guard Rail.............................................................................. P-7.10-6620-075 PAGE SERIAL NR. CUT REV. Rev.1 01/01 Rev.1 01/01 Rev.2 01/01 Rev.1 01/01 SECTION 8 CYLINDER Lift Cylinder (Platform Lift) ..................................................... P-8.4-6620-001 Free Lift Cylinder.................................................................... P-8.4-6620-025 Free Lift Cylinder (Platform Lift and Combi) ............................ P-8.4-6620-050 PAGE SERIAL NR. CUT REV. Rev.1 01/01 SECTION 9 CABIN/PLATFORM Platform ................................................................................. P-9.0-6620-001 Platform (Platform Lift/Fork Lift)............................................. P-9.0-6620-075 Platform (Fork Lift) ................................................................. P-9.0-6620-100 PAGE SERIAL NR. CUT REV. Rev.2 01/01 SECTION 10 MISCELLANEOUS SERVICE INF. Labels and Decals ................................................................. P-10.9-6620-001 PAGE SERIAL NR. CUT REV. Rev.2 01/01 Printed in Germany REV. 1 01/01 P-IDX-6620-002

SAFETY Printed in Germany

SAFETY Safety Symbols used in the Manual General Maintenance and Repair Safety Notes To help guide you through the manual and to highlight particular danger areas, we have used graphic illustra- tions: DANGER Read the safety notices in the truck Mainte- nance and Operator's Manuals. DANGER Failure to do so could result in severe or fatal injuries to maintenance personnel and/or other persons. ? This symbol indicates life-threatening risks ? Failure to comply with this notice may result in severe or fatal injuries to yourself or other people. Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guidelines. WARNING This symbol indicates the risk of serious injury and/or serious material damage. DANGER Follow all national/local safety regulations applicable for maintenance work, e.g. for work on higher levels. ? Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage. Failure to do so could result in severe or fatal injuries to maintenance personnel and/ or other persons. Maintenance and Repair ? CAUTION This symbol indicates the risk of minor injury and/or minor material damage. 1. Maintenance work must only be carried out in accordance with the test and maintenance pro- gram contained in the present Maintenance Manual and any applicable service notices. ? Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage. 2. Only qualified and authorised personnel may carry out work on the truck. INFORMATION 3. Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame. Contains additional information with supplementary notes and hints. 4. To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral. Only carry out cleaning with an oil separator. Protect the electrical system from dampness. OPTION These items relate to optional features not supplied with the standard version. ?????? 5. Keep the service area clean, dry and well-venti- lated. 6. Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled. Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed. 7. Neutralise and thoroughly rinse any spilled battery fluid immediately. Printed in Germany REV. 1 4/00 M/P-MA-0000-001 1

SAFETY Warnings and Labels on the Truck 8. Keep the truck clean. This will facilitate the loca- tion of loose or faulty components. During regular maintenance check that the warnings and labels on the truck are complete and legible. 9. Make sure that capacity and data plates, warnings and labels are legible at all times. Clean any illegible labels. ? 10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown. Replace any faulty or missing labels. ? The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual. 11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck. Before Leaving the Truck Stop the truck. ? Lower the fork carriage fully. ? Apply the parking brake. ? Turn off the travel switch and remove the key. ? Block all wheels when parking on an uneven surface. ? Before Carrying out Work on the Truck Raise the truck to free the drive wheel. Press the emergency Stop button and disconnect the battery. ? Prevent the truck from rolling away. ? Before carrying out work on the hoist frame, the lift mast or on the fork carriage: Block these parts according to maintenance instructions in order to prevent them from dropping. ? Only carry out operational testing when there is sufficient room to manoeuvre, to avoid the risk of injury to yourself and others. ? Before Operating the Truck Check the safety devices. ? Get into the driver's seat. ? Check the operation of the lifting device, travel direction switch, speed control, steering, warning devices and brakes. ? Printed in Germany REV. 1 4/00 M/P-MA-0000-002 2

INTRODUCTION Printed in Germany

INTRODUCTION General series. Brochures can be obtained from your CROWN dealer or from the following address: The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck components. CROWN Gabelstapler GmbH Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133 It also contains troubleshooting sections which can be used to identify and remedy truck faults. INFORMATION This book is not an operating manual. It is designed solely for specialist personnel who have been trained and authorised to carry out the work described in the manual. This manual therefore contains fewer and less detailed warnings than the Operator's Manual, as the latter is aimed at persons who have very little or no prior experience at all. Operating Instructions This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle. Additional copies can be ordered as required. With the help of this manual you and your personnel will be able to ensure the long service life, operational safety and error free functioning of your CROWN vehicle. Service Training CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request. Ordering Spare Parts The maintenance manual does not cover spare parts. These are listed in a separate manual. Spare parts can be ordered by quoting: The truck specification number ? The truck model number ? The truck serial number ? This information can be found on the truck's data plate. Only if this information is provided can the order be processed quickly, correctly and reliably. Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this Printed in Germany REV. 1 01/01 P-ITD-6620-001 1

INTRODUCTION Page Numbering in the Manual The page numbers are on the left and right-hand sides of the page footer. If a page has been modified since the last edition, a revision number will be found in the middle of the footer: 02 REV. 2/99 means the second amendment to this page in February 1999. The page numbers are not necessarily consecutive! The back page of the manual contains a print number in the following form: MS-ESR4000-GB-D-F 02/00 In this example, 02/00 is the edition date. A page beginning with M/P- is identical in both the maintenance and spare parts manuals: M/P-1.2-6620-001 M = Maintenance Manual P = Spare Parts Manual Chapter Page Number Section Truck Code e.g. 1.2 = Test and Maintenance Schedule (Pages which are identical for all trucks are given the code 0000 here) A page beginning with M- is only contained in the maintenance manual: M-1.2-6620-001 M = Maintenance Manual Chapter Page Number Section Truck Code e.g. 1.2 = Test and Maintenance Schedule (Pages which are identical for all trucks are given the code 0000 here) Printed in Germany M/P-ITD-6620-002 2

INTRODUCTION A page beginning with P- is only contained in the spare parts manual: P-1.0-6620-001 P = Spare Parts Manual Chapter Page Number Section e.g. 1.0 = Panels Truck Code (Pages which are identical for all trucks are given the code 0000 here) Model-Number GPC2020 Modeldescription Low Level Order Picker, 1.600 kg capacity GPC2040 Modeldescription Low Level Order Picker, 2.000 kg capacity GPC2040S Modeldescription Rider Pallet Truck with Steering Wheel, 2.000 kg capacity Printed in Germany M/P-ITD-6620-003 3

LUBRICATION Printed in Germany

LUBRICATION L u c i r b a n t T y p e P r o d t c u D e s p i r c o i t n M a a f u n t c u r e r C R O W N - - t r a P . o N T y p e u l a r A M L e R e B P E o M n i t e R b e r e H s A E L e 2 P 2 - P l a r A a C e C s E a M o M h S G u l u g c a 2 u l i b - a s n l o r t s y r u t n o s l o x l i b l l e G e r a s e ( i t l u m r u p p o ) e s o 2 0 5 3 0 0 - 2 0 0 1 B x x e L E X 2 a u l a r A e r i n U b x e S e t o L K L m 2 p l a r A o M 0 5 3 0 0 - 2 0 0 5 B B e r g a s e L o w e t m p e t a r u r e E P l i b K E l a u l o s a v l e D o s w 4 b 0 e 1 l a r A s E o M L c i r b u o i t a n c ( l i o ) n i a h H 4 D 0 X u l P s + 4 0 s l i b o 0 5 3 0 0 - 2 0 0 7 G c 2 o c i r b u l L w e t o i t a m p n e t a r l i o u r e S H C 6 2 6 M l i b o 0 5 3 0 0 - 2 0 0 8 G G a t i V y H m n i p s o t u N E T D u l l e T F W A 2 3 4 2 3 G 3 2 3 - S l a r A a C s E o M h S 2 l o r t s o s l i b l l e H a r d y c i l u l i o H 2 s 0 5 3 0 0 - 1 0 0 3 D s i v i n U o r e A J F 1 A 3 l a r A o M L w a r d y h o e t c i l u m p l i o e t a r u r e 0 5 3 0 0 - 1 0 0 8 D D H l i b H G M y X o a r i p S p 8 5 D W 8 e b M 0 W H B 9 5 l a r A s E o M h S - 9 0 9 / 5 8 0 s l i b l l e o a r T n s o i s s i m n l i o 0 5 3 0 0 - 2 0 0 4 A u l i b D 9 0 x L a r t o w n e t m s m s i p e t a r l i o n u r e M u l i b o b e S H C M l i b o 0 5 3 0 0 - 2 0 0 6 A A o i s R u r e b b a n d n i v l y e r d n i s s g H S p l a i c e e r g a s e M O S u i h t i L m D o w r o C n i n g 0 6 3 0 0 - 2 0 2 2 M 2 v i n U s r e u l l a c i r b o i t a n l i o S A E 4 0 C L01-gb Printed in Germany P-1.1-6620-002 1

LUBRICATION G r e a s e n i o P n I / s t e t r l a v 1 o 0 u 0 r 2 o 5 u 0 r 5 o 0 u 0 r 1 h 0 o 0 u 0 s r 2 h 0 o 0 u 0 r e t I m C o m p o n e n t T y p . l o V h s h s h s s 1 H a r d y c i l u e r v r e s , r i o c h e c k D / D D A / R X X X X X 2 H a r d y c i l u e r v r e s r i o D / D D A / R X X X c h a n g e 3 v i P t o n i p c l o r t n o h a e l d n C A / R X v i P G ( t o P n i p 2 C l o r t n o 0 2 / 0 4 c h S a ) e l d n a r b k e o i t p o n 4 C A / R X 0 4 0 l o r t n o r e v e l C h t o a e l d n c t a l n i h g m e c h s i n a m , 5 C A / R X v i p 6 y r e t t a B c o m t r a p m d i l t n e n i h g e C A / R X 7 y r e t t a B c t a l h B / B B A / R X 8 y r e t t a B c o m t r a p m t n e s r e l l o r B / B B A / R X t a e e m S n i h s i n a h g e m s a n d c t a l e d n i h g 9 C A / R X c 1 0 M t s a c h a n s l e n B / B B A / R X 1 1 t f i L c n i a h G / G G A / R X 1 2 e t S r e c n i a h G / G G A / R X 1 3 G b r a e o x r u t a t n e l b b n i r a e g B / B B A / R X 1 4 C , r e t s a l l a e x p o s e d e r h t a d s B / B B A / R 1 5 n i l t f i L k a g e e r r a o t p a n d o t t o b m B / B B A / R X 1 6 n i l t f i L k a g e o r f t n B / B B A / R X 1 7 v i P t o n i p o l a d w h l e e m o n i t n u g B / B B A / R 1 8 G b r a e o x l i o c h a n g e A / A A A / R X 1 9 o l l o F w u p g b r a e o x l i o c h a n g e A / A A A / R X L02-GB Printed in Germany 2 P1.2-6620-002

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ELECTRICAL DIAGRAMS Printed in Germany

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