service manual instant download

1. Parts Manual
Ersatzteilhandbuch
Manual de pièces detachés GPC 2000 Series
U1-Parts.p65 02.02.01, 09:42
1

2. Printed in Germany
TABLE OF CONTENT

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

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

5. Printed in Germany
SAFETY

6. Printed in Germany
1
M/P-MA-0000-001
SAFETY
REV. 1 4/00
OPTION
Safety Symbols used in the
Manual
To help guide you through the manual and to highlight
particular danger areas, we have used graphic illustra-
tions:
DANGER
This symbol indicates life-threatening risks
l Failure to comply with this notice may
result in severe or fatal injuries to yourself
or other people.
WARNING
This symbol indicates the risk of serious
injury and/or serious material damage.
l Failure to comply with this notice may
result in severe injuries to yourself or other
people and/or serious material damage.
CAUTION
This symbol indicates the risk of minor
injury and/or minor material damage.
l Failure to comply with this notice may
result in minor injuries to yourself or other
people and/or minor material damage.
INFORMATION
Contains additional information with
supplementary notes and hints.
OPTION
These items relate to optional features not
supplied with the standard version.
General Maintenance and Repair
Safety Notes
DANGER
Read the safety notices in the truck Mainte-
nance and Operator's Manuals.
l Failure to do so could result in severe or
fatal injuries to maintenance personnel
and/or other persons.
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.
DANGER
Follow all national/local safety regulations
applicable for maintenance work, e.g. for
work on higher levels.
l Failure to do so could result in severe or
fatal injuries to maintenance personnel and/
or other persons.
Maintenance and Repair
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.
2. Only qualified and authorised personnel may
carry out work on the truck.
3. Always keep fire extinguishers in good working
condition. Do not approach fluid levels or leaks
with a naked flame.
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.
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.

7. Printed in Germany
2
M/P-MA-0000-002
SAFETY
REV. 1 4/00
8. Keep the truck clean. This will facilitate the loca-
tion of loose or faulty components.
9. Make sure that capacity and data plates, warnings
and labels are legible at all times.
10. Alterations or modifications by the owner or
operator are not permitted without the express
written authorisation from Crown.
11. Only use original Crown spare parts to ensure the
reliability, safety and suitability of the Crown truck.
Before Leaving the Truck
l Stop the truck.
l Lower the fork carriage fully.
l Apply the parking brake.
l Turn off the travel switch and remove the key.
l Block all wheels when parking on an uneven
surface.
Before Carrying out Work on the Truck
l Raise the truck to free the drive wheel. Press the
emergency Stop button and disconnect the
battery.
l Prevent the truck from rolling away.
l 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.
l 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
l Check the safety devices.
l Get into the driver's seat.
l Check the operation of the lifting device, travel
direction switch, speed control, steering, warning
devices and brakes.
Warnings and Labels on the Truck
During regular maintenance check that the warnings
and labels on the truck are complete and legible.
l Clean any illegible labels.
l 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.

8. Printed in Germany
INTRODUCTION

9. Printed in Germany
1
INTRODUCTION
P-ITD-6620-001
series. Brochures can be obtained from your CROWN
dealer or from the following address:
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
General
The present manual is designed for Customer Service
engineers who wish to familiarise themselves with the
maintenance work required for the various truck
components.
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:
l The truck specification number
l The truck model number
l 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
REV. 1 01/01

10. Printed in Germany
2
INTRODUCTION
M/P-ITD-6620-002
Truck Code
(Pages which are
identical for all trucks
are given the code 0000
here)
Page Number
A page beginning with M- is only contained in the maintenance manual:
M/P-1.2-6620-001
P = Spare Parts Manual
Chapter
Section
e.g. 1.2 = Test and
Maintenance
Schedule
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.
M = Maintenance Manual
M-1.2-6620-001
Chapter Page Number
Section
e.g. 1.2 = Test and
Maintenance
Schedule
M = Maintenance Manual
A page beginning with M/P- is identical in both the maintenance and spare parts manuals:
Truck Code
(Pages which are
identical for all trucks
are given the code 0000
here)

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

12. Printed in Germany
LUBRICATION

13. Printed in Germany
1
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15. Printed in Germany
2
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i
o
x
o
b
r
a
e
G A
A
/
A R
/
A X
9
1 e
g
n
a
h
c
l
i
o
x
o
b
r
a
e
g
p
u
w
o
l
l
o
F A
A
/
A R
/
A X

16. Printed in Germany
ELECTRICAL DIAGRAMS