service repair manual

1. M
Revision: A • Printed in Germany
MAINTENANCE MANUAL
GPC 3000 SERIES
Bestell Nummer: 812571-006

2. 3
TABLE OF CONTENTS

3. TABLE OF CONTENTS
I
GPC 3000
TABLE OF CONTENTS
SAFETY PAGE SERIAL NO. CUT REV.
Symbols and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fork direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Text Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance and Repair Instructions . . . . . . . . . . . . . . . . . . . 6
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Parking the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Working on the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Starting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warning and Instruction Decals on the Truck . . . . . . . . . . . . . 6
INTRODUCTION PAGE SERIAL NO. CUT REV.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Subsequent Attachments and Modifications . . . . . . . . . . . . . 11
Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Contact Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICATION & ADJUSTMENT PAGE SERIAL NO. CUT REV.
Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the truck with a crane . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the truck with a forklift truck . . . . . . . . . . . . . . . . . . . . . 16
Towing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Towing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Jacking up the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Jacking up the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Taking the Truck out of Service . . . . . . . . . . . . . . . . . . . . . . . . 18
Testing Re-Commissioned Trucks . . . . . . . . . . . . . . . . . . . . . 18
Restoring the Truck to Service . . . . . . . . . . . . . . . . . . . . . . . . 18
Recommended Lubricants and Accessories . . . . . . . . . . . . . 19
Cold Store Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GPC 3020/40/60 Inspection and Lubrication Points . . . . . . . 25
GPC 3045 Inspection and Lubrication Points . . . . . . . . . . . . 27
GPC 3055 Inspection and Lubrication Points . . . . . . . . . . . . 29
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HYDRAULIC SYSTEM PAGE SERIAL NO. CUT REV.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Hydraulic Lines and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . 35
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4. TABLE OF CONTENTS
II
GPC 3000
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Replacing relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Testing and adjusting the relief valves . . . . . . . . . . . . . . . . . .37
RV1 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
RV2 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Adjusting RV1/RV2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Hydraulic unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Hydraulic unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
1.2 kW hydraulic unit disassembly . . . . . . . . . . . . . . . . . . . . .38
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
2.2 kW hydraulic unit disassembly . . . . . . . . . . . . . . . . . . . . .41
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Bleeding and Flushing the System . . . . . . . . . . . . . . . . . . . . .44
Before flushing and bleeding the system . . . . . . . . . . . . . .44
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
DRIVE UNIT PAGE SERIAL NO. CUT REV.
Changing the Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . .49
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Replacing the shaft seal of the driven shaft . . . . . . . . . . . . . .52
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Removing the driven shaft . . . . . . . . . . . . . . . . . . . . . . . . .53
Driven shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Drive Wheel and Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . .55
Drive Wheel Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Replacing the Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Replacing the Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Drive Transmission Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Repairing the Drive Transmission Unit . . . . . . . . . . . . . . . . . .58
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
ELECTRICAL SYSTEM PAGE SERIAL NO. CUT REV.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Wire colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Contact Symbol Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . .66
Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
GPC 3020/40/60 without Platform Lift . . . . . . . . . . . . . . . . . . .70
GPC 3040/60 with Platform Lift . . . . . . . . . . . . . . . . . . . . . . . .73

5. TABLE OF CONTENTS
III
GPC 3000
GPC 3045 with Platform Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 77
GPC 3055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Operator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Operator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Service Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Access 2 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Access 3 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Access 5 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Test Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Parameter Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Parameter Setting for the GPC 3020 . . . . . . . . . . . . . . . . . . 106
Parameter Setting for all Trucks except the GPC 3020 . . . . 107
Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Power Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Servicing and Replacing the Control Modules . . . . . . . . . . .111
Discharging the Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . .111
Servicing the Control Modules . . . . . . . . . . . . . . . . . . . . . . . .111
Replacing Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . .111
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Access 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Event Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Access 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Drive Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Drive Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Repairing the Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Dismantling the Rotor Assembly . . . . . . . . . . . . . . . . . . . 133
Assembling the Rotor Assembly . . . . . . . . . . . . . . . . . . . 133
Final task: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Steer Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

6. TABLE OF CONTENTS
IV
GPC 3000
Steer Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Repairing the Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Steer Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . .135
Steer Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Final task: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . .136
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . .136
1.2 kW Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
2.2 kW Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Controller Safety Test (PMT) . . . . . . . . . . . . . . . . . . . . . . . . . .141
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Carrying out the PMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Testing Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Testing Access 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
BRAKE SYSTEM PAGE SERIAL NO. CUT REV.
Electromechanical Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Servicing the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Measuring the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Replacing the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Installing a wear part kit . . . . . . . . . . . . . . . . . . . . . . . . . .146
Replacing the brake in full . . . . . . . . . . . . . . . . . . . . . . . .148
STEERING PAGE SERIAL NO. CUT REV.
Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Steering Assembly Components . . . . . . . . . . . . . . . . . . . . . .154
Steering Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . .154
Steering Assembly Installation . . . . . . . . . . . . . . . . . . . . . . .154
Final tasks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Repairing the Steering Transmission . . . . . . . . . . . . . . . . . . .155
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

7. TABLE OF CONTENTS
V
GPC 3000
Final tasks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
LIFTING MECHANISM PAGE SERIAL NO. CUT REV.
GPC 3020/40/60 Fork Height . . . . . . . . . . . . . . . . . . . . . . . . . 159
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Adjusting the Height of the Lowered Forks . . . . . . . . . . . . . 159
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Freedom of Movement of Chain Links . . . . . . . . . . . . . . 163
Chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Chain Anchor and Pulleys . . . . . . . . . . . . . . . . . . . . . . . 164
Worn Connection Plates . . . . . . . . . . . . . . . . . . . . . . . . . 164
Protruding or Turned Chain Pins . . . . . . . . . . . . . . . . . . 164
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Side wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Tools and Equipment Required . . . . . . . . . . . . . . . . . . . . 168
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Checking the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Crack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
CYLINDERS PAGE SERIAL NO. CUT REV.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
For your personal protection . . . . . . . . . . . . . . . . . . . . . . 173
Hydraulic System Repair Instructions . . . . . . . . . . . . . . . . . 173
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Producing extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Protective mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Gasket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Old Gasket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Large Gasket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Small Gasket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Rod Seal Assembly, Sealing Lip First . . . . . . . . . . . . . . . 177
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Replacing the Rod Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

8. TABLE OF CONTENTS
VI
GPC 3000
SCHEMATIC DIAGRAMS PAGE SERIAL NO. CUT REV.
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
With Key Switch and Keypad . . . . . . . . . . . . . . . . . . . . . . . . .184
TCM - Combi AC1 Power Side . . . . . . . . . . . . . . . . . . . . . . . .185
TCM - Combi AC1 Logic Side . . . . . . . . . . . . . . . . . . . . . . . . .186
SCM - EPS AC0 Logic Side . . . . . . . . . . . . . . . . . . . . . . . . . . .187
Interface #1 Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Interface #2 Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
GPC3045, 3055 Connections . . . . . . . . . . . . . . . . . . . . . . . . . .191
Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Handle Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Display with Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
CAN Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Power Cables GPC 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
Harness, Walk Beside Switch . . . . . . . . . . . . . . . . . . . . . . . . .199
GPC3055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Beside Switch Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
GPC3055 (no PPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
CAN Interface Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
GPC3055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Lift / Lower Scissors Harness . . . . . . . . . . . . . . . . . . . . . . . . .203
GPC3040 / 3060, GPC3045 . . . . . . . . . . . . . . . . . . . . . . . . .203
Scissors RAS - LOS Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
GPC3055 (no PPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Walk Beside Switch Harness F/C . . . . . . . . . . . . . . . . . . . . . .205
Microswitch Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Horn Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
Horn Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
SAS Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Main Harness GPC 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
X10 Handle Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Display Harness GPC 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . .217
Adapter ZAPI Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
BRK Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
X10 - Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .220
GPC 3000 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
CAN-Tiller Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . .221
GPC Standard 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Steer Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Walk Beside Switch Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Platform Lift Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Backrest Harness #2 Platform Lift . . . . . . . . . . . . . . . . . . . . .226
Straight Ahead Sensor Assy . . . . . . . . . . . . . . . . . . . . . . . . . .227
CAN Interface Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
Lift Lower Scissors Harness GPC 3000 . . . . . . . . . . . . . . . . .229
LMS Harness Scissors Lift . . . . . . . . . . . . . . . . . . . . . . . . . . .230
Scissors RAS - LOS Assy GPC 3000 . . . . . . . . . . . . . . . . . . .231
Platform Lift Fork Switch Assembly RAS / LOS 2-5 . . . . . . .232
Backrest Harness #2 Platform / Forks . . . . . . . . . . . . . . . . . .233
Battery Latch Switch (BLS) Assy . . . . . . . . . . . . . . . . . . . . . .234
Adapter Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
Walk Beside Switch Harness F/C . . . . . . . . . . . . . . . . . . . . . .236
Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238

9. TABLE OF CONTENTS
VII
GPC 3000
Connection Cable Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Connection Cable DC / DC Converter . . . . . . . . . . . . . . . . . . 240
DC / DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
HYDRAULIC SCHEMATIC PAGE SERIAL NO. CUT REV.
GPC 3020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
GPC 3040/3045/3060 without Platform, GPC 3055 . . . . . . . . 246
GPC 3040/3045/3060 with Platform . . . . . . . . . . . . . . . . . . . . 247

10. 1
SAFETY

11. SAFETY
Symbols and Indicators
5
GPC 3000
Symbols and Indicators
Safety Symbols
The following symbols will help you to assess the risk
to yourself, other people and materials should you fail
to comply with a safety notice:
DANGER
This symbol warns of immediate danger to the life and
health of personnel.
Severe injury or death will result.
Follow all instructions indicated by this symbol in order
to avoid injury or death.
WARNING
This symbol warns of immediate danger to the health
of personnel.
Severe injury or death may result.
Follow all instructions indicated by this symbol in order
to avoid injury or death.
CAUTION
This symbol warns of possible danger to the health of
personnel.
Injury may result.
Follow all instructions indicated by this symbol in order
to avoid injury.
NOTE
This heading warns of material damage and indicates
additional information.
General Symbols
Fork direction
These symbols are used to show the direction of view
in a figure. The direction of the forks is used as refe-
rence:
General Text Indicators
1., 2., 3. denote work steps to be taken.
1, 2, 3 etc. indicate item numbers in illustrations.
• denotes lists.

12. SAFETY
General Safety Instructions
6
GPC 3000
General Safety Instructions
Maintenance and Repair Instruc-
tions
DANGER
Observe the safety instructions contained in the main-
tenance manual, the operator manual and on the truck.
Failure to do so could result in serious or even fatal
injuries to maintenance and other personnel.
Motorised trucks can become hazardous if mainte-
nance and servicing work are neglected. Maintenance
and repairs must therefore be carried out in short inter-
vals. Appropriate safety guidelines, qualified and
trained staff are basic requirements for avoiding risks.
Maintenance and Repair
• Work must be performed in accordance with these
service instructions and relevant service bulletins.
• Only qualified and authorized personnel may carry
out work on the truck.
• Keep fire protection equipment at hand and do not
use a naked flame to check fluid levels or to test for
leaks.
• Use groundwater neutral, non-flammable solvents
for cleaning. Always perform cleaning work over an
oil separator. Protect the electrical system against
damp.
• Keep the work place and battery charging station
clean, dry and well ventilated.
• Do not allow oils to penetrate the ground or the
drain system. Used oil must be recycled correctly.
Oil filters and dehumidifying inserts must be
treated as special waste. Observe the local author-
ity regulations.
• Immediately neutralize and thoroughly rinse any
spilled battery fluid.
• Keep the truck clean. This will facilitate tracing
loose or faulty components.
• Maintain the legibility of the data capacity plate and
data plate, warning and instruction decals.
• Truck modifications and additions may only be per-
formed with Crown’s prior written approval.
• The reliability, safety and suitability of Crown trucks
can only be ensured by using original Crown parts.
Before Parking the Truck
• Brake until the truck comes to rest.
• Lower the fork carriage fully.
• Apply the parking brake.
• Switch off the truck and remove the key.
• When parking on a slope or incline always chock
all wheels.
Before Working on the Truck
• Jack up the truck so that the drive wheel is clear of
the ground. Apply the Emergency power discon-
nect switch and disconnect the battery.
• Prevent the truck from rolling away and lowering.
• When working on the mast, fork carriage or lifting
mast always apply a chock to prevent accidental
lowering.
• Allow sufficient room for manoeuvre when testing
the truck, to avoid endangering yourself and other
people.
Before Starting the Truck
• Test the safety mechanisms.
• Get into the travel position.
• Test the lifting mechanism, travel switch, speed
control, steering, warning mechanism and brakes.
Warning and Instruction Decals on
the Truck
In the course of periodic maintenance work, check that
the warning and instruction decals on the truck are
complete and legible.
• Clean any dirty decals.

13. SAFETY
General Safety Instructions
7
GPC 3000
• Replace any faulty or missing decals.
The spare parts manual gives details of the labelling
and arrangement of the warning and instruction decals
on the truck.

14. 9
INTRODUCTION

15. INTRODUCTION
General
11
GPC 3000
General
NOTE
This manual is intended only for trained, specialist per-
sonnel who are authorised to carry out the tasks de-
scribed.??
Service training
Crown offers appropriate truck-related training for serv-
ice personnel. Ask for details.
Replacement Parts
This manual does not contain a spare parts list. Re-
placement parts can be found in the spare parts cata-
log.
Subsequent Attachments and Modi-
fications
DANGER
Untested modifications can lead to fatal accidents.
Any modification which alters the original condition of
the truck requires prior testing and approval in writing
by Crown (see contact address).
• The weight and position of attachments can have a
significant affect on the capacity and other features
of the truck.
• Modifications to the electrical system or the subse-
quent installation of electric-poweredcomponents
can damage the truck.
Using the Manual
Contact Address
:
Section Table of Contents
IDX Table of Contents
MA Safety
ITD Introduction
1 Lubrication & Adjustment
2 Hydraulic System
3 Drive Unit
4 Electrical System
5 Brake System
6 Steering
7 Lifting Mechanism
8 Cylinders
9 Platform
10 Glossary
CROWN Gabelstapler GmbH & Co.KG
Moosacher Str. 52
80809 Munich
GERMANY
Tel.: +49 (0)89 / 93 002 -0
Fax: +49 (0)89 / 93 002 -175 or 133

16. INTRODUCTION
Models
12
GPC 3000
Models
The manual covers maintenance and repair work for
the following models:
:
GPC 3020
GPC 3040
GPC 3060
GPC 3045
GPC 3055

17. 13
LUBRICATION & ADJUSTMENT

18. LUBRICATION & ADJUSTMENT
Lifting and Jacking
15
GPC 3000
Lifting and Jacking
WARNING
Scalding hazard
Charged batteries are dangerous. The transport of
charged batteries is governed by special regula-
tions.
Failure to comply with safety regulations can result in
serious personal injury and damage to the transported
goods.
• Follow the national and international regulations
concerning the transport of acid-filled batteries.
• Contact your freight company for details of relevant
shipping conditions.
CAUTION
Scalding hazard
• You must remove the battery before transporting
the truck.
This will prevent possible leakage of battery acid in the
truck and resulting material or personal damage.
Lifting the Truck
DANGER
Danger of death
Fatal injuries can result from a crane or lift truck tipover,
or a falling load.
• Make sure the crane, truck and the lifting gear have
sufficient capacity.
Information on the capacity required can be found
on the truck data plate under “Truck Weight Less
Battery” and “Battery Weight”.
Lifting the truck with a crane
1. Fully raise the forks.
1. Fully lower the forks.
2. Attach chains and hooks to the cutouts in the floor-
board in front of the battery compartment.
3. Push a thin board on either side between the truck
and the chain.
4. Sling the lifting belts around the forks (see Fig.
GPC840Fig. GPC860 or GPC861).
GPC840
GPC860

19. LUBRICATION & ADJUSTMENT
Lifting and Jacking
16
GPC 3000
Lifting the truck with a forklift truck
1. Fully lower the forks.
2. Position the forks of the truck that is doing the lifting
under the chassis of the lift truck (see
Fig. GPC841).
3. Attach the truck securely onto the forks of the truck
doing the lifting (e. g. with a tensioning belt).
Towing the truck
DANGER
Danger of death
A truck tipover can result in fatal injuries.
• Make sure the truck has sufficient capacity.
Information on the capacity required can be found
on the truck data plate under “Truck Weight Less
Battery” and “Battery Weight”.
NOTE
In order to be towed, the motor compartment side of
the truck must be raised so that the drive wheel does
not contact the ground. Otherwise the drive wheel
would be damaged since the truck brakes are applied
when the truck is switched off.
Towing the truck
1. Fully lower the forks (if possible).
2. Position the forks of the towing truck under the
truck.
3. Raise the motor compartment side of the truck
approx. 20 mm.
4. Pull the truck slowly and only in a forward direc-
tion (as indicated by the arrow in GPC842).
GPC861
GPC841
GPC842
1
3
4 4
2 2

20. LUBRICATION & ADJUSTMENT
Lifting and Jacking
17
GPC 3000
Jacking up the truck
DANGER
Danger of death
You can be fatally injured by a truck tipover.
• Make sure the jack has sufficient capacity.
Information on the capacity required can be found
on the truck data plate under “Truck Weight Less
Battery” and “Battery Weight”.
DANGER
Danger of death
Fatal accidents can result from improper handling of
the truck or the equipment.
• Never place your hands or other parts of your body
under the truck before it has been supported.
• Always support a raised truck with wooden blocks
or other suitable equipment to relieve the jack.
Jacking up the truck
1. Fully lower the forks.
2. Place the jack in the centre of the left hand side of
the skirt (castor wheel) and raise the truck a
maximum of 20 mm (1, Fig. GPC834).
3. Place hard wooden blocks under the front and rear
left of the chassis and lower the truck onto them
(2).
4. Raise the right side in the same way as the left side
(3).
5. Place hard wooden blocks underneath and lower
the truck (4).
GPC834
1
3
4 4
2 2

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22. LUBRICATION & ADJUSTMENT
Taking the Truck out of Service
18
GPC 3000
Taking the Truck out of Service
If the truck is to be out of service for more than
3 months, proceed as follows:
1. Disconnect the battery from the truck's circuit.
2. De-commission the battery in accordance with the
manufacturer‘s instructions.
3. Clean and then lubricate the truck.
NOTE
Note the following when cleaning the truck:
• Do not use pressure jets and/or solvents on the
truck.
• Do not use metal brushes.
• Do not wet-clean the electrical system.
• Do not use flammable cleaning agents.
• Think of the environment.
4. If possible store the truck in a dry room with as
constant a temperature and air humidity as
possible.
Do not park the truck outdoors or in a humid
environment.
5. If the truck has to be stored in hostile conditions
(e. g. saline atmosphere) treat the surface of the
truck with a suitable preservative to prevent
corrosion.
6. If the truck has to be stored in excessively dusty
conditions, cover it with a permeable material and
not plastic sheets as these can allow condensation
water to form.
7. Jack up the truck (see page 17), as otherwise the
constant pressure can cause the wheels to flatten.
Testing Re-Commissioned Trucks
NOTE
The hydraulic system must be operated every
3 months to ensure its functionality over the period of
storage.
Test
1. Connect the battery.
2. Check the hydraulic oil level.
3. Check the gear unit for leaks.
4. Check the anti-corrosion agent.
5. Disconnect the battery.
Restoring the Truck to Service
To restore the truck to service, proceed as follows:
1. Remove the anti-corrosion agent.
2. Jack up the truck, remove the wooden blocks and
lower the truck.
3. Charge the battery or fit a charged battery.
4. Connect the battery.
5. Carry out the daily safety inspection.

23. LUBRICATION & ADJUSTMENT
Recommended Lubricants and Accessories
19
GPC 3000
Recommended Lubricants and
Accessories
The tables show typical lubricants used by Crown itself
in its facilities. However, you can use any lubricants
provided they meet the same technical criteria.
Cold Store Trucks
Special hydraulic oil, lubrication oil and grease must be
used for cold store trucks operating in low temperature
conditions (see table).
An anti-corrosion fluid (Crown no. 805236-004) must
be applied to all screws, washers, nuts, pins, retaining
rings etc. Carefully protect all electrical connections
and components against corrosion. For detailed infor-
mation, refer to chapter Electrical System.
Service intervals (see page 21) must be adapted to the
conditions of use.
Type Lubricant Type Product Manufacturer Crown
Part Number
A
Transmission oil Hyp 85W90 Aral
053002-004
GX-D 85W90 Esso
Mobilube HD85W90 Mobil
Spirax MB90 Shell
AA
Low temperature transmis-
sion oil
Mobil SHC 624 Mobil
053002-009
B
Grease (Multi-Purpose) Aralube HLP2 Aral
053002-001
LM Grease Castrol
Regulus A2 Century
Beacon EP2 Esso
EP2 Maxol
Mobiluxe EP2 Mobil
Retinax LX Shell
ALGWMI SKF
BB
Low temperature grease Aralube SKL2 Aral
053002-005
Unirex Lotemp EP Mobil
D
Hydraulic Oil Vitam GF 32 Aral
053001-003
Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil
Tellus 32 Shell
Hydran LZ 32 Finol
B110 Fuchs Mineralöl-
werke GmbH
DD Hydraulic Oil (Low Temp) Deutz Oel HVI 32 Klockner 053001-009