Maintenance Manual
GPC2000 Series Rev. B • Printed in Germany Order Number: 812520-006
This master maintenance manual is subject to continual updates. It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH - European Headquarter Moosacher Str. 52 80809 Munich Germany Phone +49 (0)89 93 00 2 – 0 Fax +49 (0)89 93 00 2 – 133
All rights reserved under international and Pan-American Copyright Agreement. Copyright 2002 CROWN Equipment Corporation
TABLE OF CONTENT
Printed in Germany
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M1.0-0000-000II M1.0-0000-000II II
TABLE OF CONTENT Table of Content MA – SAFETY
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Safety Symbols used in the Manual ................................... 3 ................................................................ Rev.1 04/00 General Maintenance and Repair Safety Notes ................... 3 Maintenance and Repair .................................................... 3 ................................................................ Rev.1 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
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General ................................................................................. 7 Operating Instructions ....................................................... 7 Service Training ................................................................. 7 Ordering Spare Parts ........................................................ 7 Using the Manual .............................................................. 7 Model-Number ................................................................... 8
M1 – LUBRICATION AND ADJUSTMENT
PAGE
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
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
MS-GPC2000-GB • Rev. A • Printed in Germany
III
TABLE OF CONTENT M3 – DRIVE UNIT
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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
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 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
IV
TABLE OF CONTENT M4 – ELECTRICS
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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
MS-GPC2000-GB • Rev. A • Printed in Germany
V
TABLE OF CONTENT M4 – ELECTRICS
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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
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 1.6 t, Brake Default Setting ........................ 115 GPC 2040 Standard 2.0 t, Brake Default Setting ......... 115 GPC 2040 High Lift and Twin Lift 1.0 t, Brake Default Setting ----------------- 115 Brake Test ............................................................................. 116 Braking Distance Setting .................................................. 116 GPC 2020 Standard 1.6 t .................................................. 116 Braking Distance with Max. Load ................................. 116 Braking Distance with Truck Unladen ........................... 116 GPC 2040 Standard 2.0 t .................................................. 116 Braking Distance with Max. Load ................................. 116 Braking Distance with Truck Unladen ........................... 116 GPC 2040 High Lift and Twin Lift 1.0 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
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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 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
VI
TABLE OF CONTENT M6 – STEERING
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Forward Travel Setting for Electrical Steering ............... 129 Steering Chain ..................................................................... 130 Chain Tension Adjustment ................................................. 130
M7 – LIFTING MECHANISM
PAGE
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
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
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
MS-GPC2000-GB • Rev. A • Printed in Germany
VII
TABLE OF CONTENT DIA – ELECTRICAL DIAGRAMS
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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
2020/2040/2040S .............................................................. 181 Platform Lift ...................................................................... 182 Fork Lift ............................................................................ 183 Platform/ Fork Lift ............................................................. 184
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
VIII
SAFETY
Printed in Germany
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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 illustrations:
DANGER Read the safety notices in the truck Maintenance 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.
WARNING This symbol indicates the risk of serious injury and/or serious material damage.
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.
● 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.
CAUTION This symbol indicates the risk of minor injury and/or minor material damage.
Maintenance and Repair 1.
Maintenance work must only be carried out in accordance with the test and maintenance program 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-ventilated.
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.
● 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 OPTION
These items relate to optional features not supplied with the standard version.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MP/MS-0000-MA
REV. 1 4/00
33
SAFETY 8.
Keep the truck clean. This will facilitate the location 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.
Warnings and Labels on the Truck During regular maintenance check that the warnings and labels on the truck are complete and legible. ●
Clean any illegible labels.
●
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.
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.
MP/MS-0000-MA
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
REV. 1 4/00
44
INTRODUCTION
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M1.0-0000-0006 M1.0-0000-0006 6
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.
Using the Manual The manual is divided into sections. The following table shows how the manual is structured.
Sections Maintenance 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.
Section
Description
IDX
Table of Content
MA
Safety
MS-ITD
Introduction
MS-1
Lubrication and Adjustment
MS-2
Hydraulics
MS-3
Drive Unit
MS-4
Electrical
MS-5
Brake
MS-6
Steering
MS-7
Mast /Lifting Mechanism
MS-8
Cylinder
DIA
Electrical Diagrams
HYD
Hydraulic Schematic A01M-gb
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
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-ITD-6620
M1.0-0000-0007 77
INTRODUCTION Model-Number This manual describes the maintenance and repairs for the following truck versions:
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
MS-ITD-6620
8 8M1.0-0000-0008
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT
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LUBRICATION AND ADJUSTMENT Jacking up the Truck CAUTION Always support a raised truck with wooden blocks or other suitable equipment, thereby relieving the jack.
If there is sufficient distance between the truck centre of gravity (e.g. 1B) and the rear end of the chassis frame the truck can be supported by placing a block under the rearFastening end of the chassis frame (instead of the forks) point A in figure above. In this case, place an extra screws wooden block under the tips of the lowered fork.
Lifting the Truck with a Crane DANGER
The instruction "jack up the truck" always assumes that the raised truck will be lowered onto a secure surface. To jack up the truck, proceed as follows (Picture MS6620-003): ●
Lift the forks to maximum height.
●
Secure both loadwheels with a wedge (1).
●
Apply a jack with sufficient capacity (> 900 kg) at the middle of the chassis frame and raise the truck (2).
Make sure the capacity of the crane and the lifting device is sufficient. If a crane or truck tips or a load falls, fatal injuries can result. For lifting the truck, the forks must be in a raised position (maximum height). In order to attach the lifting straps to the truck at the locations indicated, you must first tilt back the battery compartment cover and remove the side panels.
●
Place sufficiently sized woodenblocks (hard wood) on both sides underneath the chassis and lower the truck onto the blocks (3).
●
Apply the jack to the forks.
●
Place a wooden block under the forks and lower the truck onto it (4).
Attach the straps (ropes, chains) to the hitch points as shown in. Required lifting capacity: 730 kg for a GPC with 1000 mm forks, 870 kg for a GPC with 2880 mm forks (GPC without battery).
583 377 192
2
1
1B
1
A 3
4
2
3
MS-6620-004
MS-6620-003
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.0-6620
11
LUBRICATION AND ADJUSTMENT Lifting the Truck with a second Truck The GPC can be lifted by another truck from the side. Required lifting capacity: 730 kg for a GPC with 1000 mm forks, 870 kg for a GPC with 2880 mm forks (GPC without battery). ●
Place the forks of the truck which is doing the lifting under the GPC chassis as indicated by the black forks under the GPC in the figure below. Exception: GPC with fork length over 2000 mm and without battery. Position the forks of the truck which is doing the lifting as indicated by the grey forks under the GPC in the figure below. The forks of the GPC must be in their uppermost position. Insert a 120 mm thick block between the forks of the GPC and the corresponding fork of the lifting truck.
●
Firmly secure the GPC to the forks of the truck which is doing the lifting (e.g with appropriate straps).
583 377
Position of the truck’s centre of gravity 1B 1000 mm forks, with 385 kg battery 1 1000 mm forks, without battery 2 2880 mm forks, without battery
192
1
1B
> 600
> 800
Rear fork of the truck which is doing the lifting
120
2
MS-6620-003
MS-1.0-6620
12M1.0-0000-00012
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT Towing the Truck If the truck is without power supply, the brake is applied to the drive wheel. The truck can be partially lifted and moved by another truck with a lifting capacity of 1300 kg or more (GPC without load, with 385 kg battery and 2880 mm fork length). The load wheels remain on the floor during the procedure. ●
Position the fork under the chassis as shown.
●
Lift the truck (at the front part) approximately 20 mm off the floor.
CAUTION The drive wheel must be lifted from the floor! Otherwise the truck could be damaged. ●
Pull the truck slowly straight forward (as indicated by the black arrow).
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
400 mm
100 mm
Load Wheels
MS-1.0-6620
13
LUBRICATION AND ADJUSTMENT De-commissioning If the truck is to be out of service for 3 months or more, proceed as follows:
Re-commissioning To re-commission the truck, proceed as follows: ●
Remove any anti-corrosion film that may have been applied*).
De-commission the battery in accordance with the manufacturer‘s instructions.
●
Jack up the truck, remove the wooden blocks, lower the truck.
●
Clean the truck*). Carry out lubrication in accordance with the Maintenance Manual.
●
Charge the battery or install a charged battery.
●
Connect the battery.
●
When storing in adverse environmental conditions (e.g. saline atmosphere), take appropriate measures to cover the truck to prevent corrosion.
●
Carry out the daily inspection.
●
Disconnect the battery.
●
●
Jack up the truck, lower the chassis onto suitable wooden blocks to clear the wheels from the ground to prevent the wheels from flattening under constant pressure.
●
Every 3 months, connect the battery, carry out the daily inspection and operate all the truck functions. Finally, disconnect the battery again.
MS-1.0-6620
14M1.0-0000-00014
*) Do not use pressure jets and/or solvents with the truck! Do not use metal brushes!
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT Component Access For regular maintenance purposes the drive unit, hydraulic system, contactor panel etc. can be reached by removing the panels.
WARNING! The battery connector must always be pulled out before any maintenance work. This is particularly important if plugs and sockets have to be disconnected.
4
2 1
2
3
1
2
M0070
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.0-6620
15
LUBRICATION AND ADJUSTMENT
GPC 2040 With foot step, additional standing space above the battery compartment and protective mesh for the 2nd stockpicking level. OPTION
MS-6620-008
GPC 2040 S (with steering wheel)
MS-6620-010 MS-1.0-6620
16M1.0-0000-00016
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT Models
GPC 2040 with platform- and forklift OPTION
MS-6620-009
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.0-6620
17
LUBRICATION AND ADJUSTMENT Maintenance be reduced. The exact periods should be established after consultation with Crown service personnel.
Check and Maintenance Schedule The following check and maintenance schedule assumes single-shift operation under normal operating conditions. The length of maintenance intervals will however depend on the particular operating conditions.
When performing maintenance work always check for wear, corrosion and damage and ensure that the parts are operating correctly and are secure. If in doubt, replace them.
In dusty or otherwise extreme environments, including cold stores, the specified maintenance intervals should
Daily or every 8 service hours (Part1) No.
Item
Action
I-0
Truck*
Clean if necessary.
Battery
Check / charge battery in accordance with manufacturer's instructions.
Battery compartment
Check battery compar tment for battery acid leakage.
Battery connector
Check for damage. Check contacts for any signs of burning.
Side locks
The retaining lugs on both sides of the battery must be in the down position.
I-2
Gearbox
Check for leaks.
I-3
Hydraulic system
Check for leaks. If leaks are found, de-commission the truck.
I-4
Forks
Check for deformation, fissures and excess wear.
I-5
Wheels / load wheels
Check tyres for wear and for any foreign bodies. Remove any foreign bodies found.
I-6
Labels, decals
Ensure they are complete and legible.
I-7
Step board (if appl.)
Check if properly secured. Check for damage.
I-8
Suppor t bars (if applicable)
Check if properly secured. Check for damage.
I-9
Key Switch
Turn on the key switch and check operation of the indicators.
I-10
Lifting mechanism
Lift the forks. Check for foreign bodies. Remove any foreign bodies found using a hook. Never reach your hands into the lifting mechanism!
I-11
Emergency Disconnect
Check operation.
I-12
Horn
Check operation.
I-13
Steering
Check operation and absence of play.
I-1
I-14
Travel Functions
I-15
Brakes
Move the truck in both directions, slowly at first and then at full speed. GPC 2040 S: Also check operation of the reverse travel switch in the backrest. Check braking in both travel directions: - by reversing the travel direction via the travel switch - by releasing the safety foot switch - by pressing down the tiller (not with the GPC 2020) L02-1-gb
*) Do not use pressure jets and/or solvents with the truck! Do not use metal brushes! MS-1.1-6620
18M1.0-0000-00018
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT Daily or every 8 service hours (Part2) No.
Item
Action
I-16
pedestrian function "Quick Pic" and "Walk along"
Check operation - Travelling must be inhibited if only one of the two "Quick Pic" switches on the multitask handle / steer wheel console is pressed. - Tiller-mounted trucks: Check automatic travel stop at steering angle > 10° (not for GPC 2020). - GPC 2040 S: "Quick Pic" function in straight ahead travel direction only.
I-17
Fork lifting/lowering
Lift and lower the forks. The hydraulics must cut out when the lift / lower limit positions are reached (4-13).
I-18
Platform lifting/lowering (where applicable)
Lift and lower the platform. The hydraulics must cut out when the lift / lower limit positions are reached (4-13). Travelling must be inhibited when the platform is not in its lowest position. L02-2-gb
INFORMATION You will find figures to the points of inspection fn the operator manual of the vehicle!
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.1-6620
19
LUBRICATION AND ADJUSTMENT Monthly or every 100 service hours No.
Item
Action
I-19
Battery
Check according to the battery manufacturers manual.
I-20
Contactors
Clean; check, replace if necessary.
I-21
Electrical system
Check wires, switches and connections are secure, check insulation for damage.
I-22
Battery compar tment rollers
Clean, check for wear, replace and grease if necessary.
I-23
Brake
Blast off corrosion; check seal for damage; check air gap.
I-24
Lift cylinder
Ensure seal is tight.
I-25
Chain and chain anchor
Check for wear.
I-26
Hydraulic oil tank
Check oil level, replenish if necessary
I-27
Steering
Function check of chain tensioner.
I-28
Load wheels and castor bearings
Check for play, replace bearings if necessary.
I-29
Drive wheel
Ensure wheel nuts are correctly torqued. L03-gb
MS-1.1-6620
20M1.0-0000-00020
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT
I-28
I-29
MS-6620-013
I-28
I-24
I-25
MS-6620-012
I-28
I-23
I-26
MS-6620-014
I-27
I-19 I-20
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.1-6620
21
LUBRICATION AND ADJUSTMENT Every 3 months or 250 service hours No.
Item
Action
I-30
Truck, battery and charger connectors/plugs
Clean contacts and check contact springs
I-31
Battery cover latch
Function check, oil.
I-32
Pump and drive motor
Check commutator and carbon brushes for damage, spring tension and wear; blast dust with air.
I-33
Raiser, load wheel side plate, link inboard top/bottom
Clean raiser, check for wear and tear, replace and grease if necessary.
I-34
Tension bars, lock nut
Examine for wear, tear and secure fastening, tighten or replace tension bars if necessary.
I-35
Liftstructure
Clean bearing and surfaces, examine for waer and tear, replace and grease if necessary.
I-36
Stops on mast and fork carriage
Check for wear.
I-37
Forks
Check height setting, adjust if necessary L04-gb
Every six months or 500 service hours No.
Item
Action
I-38
Tiller
Check operation and grease recuperating spring.
I-39
Brake
Check brake lining and contact surfaces for wear, replace par ts if necessary. Check air gap and adjust if necessary.
I-40
Hydraulic cylinder
Clean upper and lower cylinder fastenings, examine for wear and tear, replace and grease if necessary.
I-41
Lift mechanism
Clean bearings and striking surfaces check for wear, replace if necessary, grease
I-42
Steering
Clean chain, grease and adjust.
I-43
Load wheel and castor axles
Clean, check for wear, replace if necessary, grease L05-gb
MS-1.1-6620
22M1.0-0000-00022
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT
I-33,I-35
I-43
I-33,I-35 MS-6620-013
I-36 I-35, I-41
I-34 I-33,I-35
I-40 I-43
MS-6620-012
I-31 I-30
I-37 I-38
I-39
I-32
I-42
MS-6620-014
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.1-6620
23
LUBRICATION AND ADJUSTMENT Annually or every 1000 service hours No
Item
Action
I-44
Pump and drive motor
Check commutator for damage and wear; blast dust with air
I-45
Hydraulic system
Change hydraulic oil; replace filter (initial replacement after 500 hours); Clean lines and connections, check tightness and sealing, tighten if necessary
I-46
Coupling lift motor/pump
Clean coupling, check for wear, if necessary replace par ts.
I-47
Gear unit
Check gear oil level, replenish if necessary.
I-48
Drive unit/Castor
Grease turntable roller bearing.
I-49
Brake
Check brake lining and contact surfaces for wear, replace par ts if necessary.
I-50
PMT-Test
Check fault detection circuit of traction controller
I-51
Hydraulik Relief Valve
Funktion check, check setting and adjust if necessary.
I-52
Carry out UVV test
Only in Germany; If applicable do tests according to local regulations and laws in appropiate intervals. L06-gb
Every 2 years or 2000 service hours No.
Item
Action
I-53
Gear unit
Change gear oil L07-gb
MS-1.1-6620
24M1.0-0000-00024
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT
I-49
I-52
I-44 I-48 I-47, I-53
I-46 I-51 I-45 I-48 I-50
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.1-6620
25
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Printed in Germany
26
LUBRICATION AND ADJUSTMENT Recommended Lubricants and Oils
typical, and any lubricant of the same grade can be used.
Lubricants Cold Store Trucks Only high grade lubricants and oils should be used. These can be obtained from any oil manufacturer. Those listed in table on page M1.1-6620-002 are
Special hydraulic oil, lubrication oil and grease must be used for cold store trucks operating in low temperature conditions (see table L01-gb). An anti-corrosion fluid (Crown no. 078882-002) must be applied to all screws, washers, nuts, pins, retaining rings etc. Maintenance schedules should be kept as short as possible to prevent excessive wear of moving components.
Lubricant Type
Product
Manufacturer Crown Part No.
Type
Grease (multi purpose)
Aralube HLP2 LM-Grease Regulus A2 Beacon EP2 EP2 Mobilux E2 Retinax LX
Aral Castrol Century Esso Maxol Mobil Shell
053002-001
B
Grease F/C (low temperature)
Aralube SKL2 Unirex Lotemp EP
Aral Mobil
053002-005
BB
Hydraulic oil
Vitam GF 32 Hyspin AWS-32 Nuto H32 DTE 24 Tellus 32
Aral Castrol Esso Mobil Shell
053001-003
D
Hydraulic oil F/C (low temperature)
Univis J 32 Aero HFA
Aral Mobil
053001-003
DD
Transmission oil
Hyp 85W90 GX - D 85W90 Mobilube HD85/90 Spirax MB90
Aral Esso Mobil Shell
053002-004
A
Transmission oil F/C (low temperature)
Mobilube SHC
Mobil
053002-006
AA
Special grease
MOS2 Lithium
Dow Corning
063002-022
M
Universal lubrication oil
SAE40
------------------
----------------
C
Transmission liquid grease
S400 TIVELA Compound A
Esso Shell
----------------
E
Lift chain grease
-------------------------------
-----------------
053002-007
F
Lift chain grease F/C (low temperature)
-------------------------------
-----------------
053002-008
FF L01-gb
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.2-6620
27
LUBRICATION AND ADJUSTMENT Grease items and grease intervals Grease Items / Grease Intervals Type
Total
100 hours
250 hours
500 hours
1000 hours
2000 hours
D/DD
A/R
X
X
X
X
X
L-2 Change hydraulic oil
D/DD
A/R
L-3 Pivot pin control handle
C
A/R
X
Item Component L-1
Check hydraulic reservoir, replenish if necessary
X
L-4
Pivot pin control handle, brake option (2040)
C
A/R
X
L-5
Control handle latching mechanism, lever pivot
C
A/R
X
C
A/R
X
L-7 Battery latch
B/BB
A/R
X
L-8 Battery compar tment rollers
B/BB
A/R
X
C
A/R
X
L-10 Mast channels
B/BB
A/R
X
L-11 Lift chain
G/GG
A/R
X
L-12 Steer chain
G/GG
A/R
X
L-13 Gearbox turntable bearing
B/BB
A/R
X
L-14 Castor, all exposed threads
B/BB
A/R
X
L-15 Lift linkage rear top and bottom
B/BB
A/R
X
L-16 Lift linkage front
B/BB
A/R
X
L-17 Pivot pin load wheel mounting
B/BB
A/R
X
L-18 Change gearbox oil
A/AA
A/R
Initial change after 250 hoursof operation
L-19 Follow up gearbox oil change
A/AA
A/R
L-6 Battery compar tment lid hinge
L-9
Seat hinges and delatching mechanism
X X L08-gb
MS-1.3-6620
28M1.0-0000-00028
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT
L-10
MS-6620-013
L-15
L-16 L-11 L-17
L-9 L-7
MS-6620-012
L-5
L-13 MS-6620-014
L-6
L-18, L-19
L-3 L-1, L-2 L-12
L-4 L-14
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
L-8 MS-1.3-6620
29
LUBRICATION AND ADJUSTMENT Torques The screw and nut strengths shown below are used in the manufacture of Crown trucks. The information on the page is designed to help determine the correct torque for maintenance work.
NOTE The torques listed in the maintenance section always supersede those shown on next page.
Screw grade marking
Nut grade marking
8 .8 8 .8 8
1 2 .9
1 2 .9 graphics: m0340_1...5
MS-1.9-0000
30M1.0-0000-00030
T01-gb
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LUBRICATION AND ADJUSTMENT Standard Screws and Nuts Grade
8 and 8.8
10 and 10.9
Thread Size
12 and 12.9
Torque (Nm)
M5 x 0.8
5-6
7-8
8 - 10
M6 x 1
8 - 10
12 - 14
14 - 16
M8 x 1.25
20 - 25
30 - 35
34 - 40
M10 x 1.5
40 - 45
60 - 65
70 - 75
M12 x 1.75
70 - 80
100 - 110
115 - 130
M16 x 2
170 - 190
240 - 270
280 - 320
M20 x 2.5
340 - 380
450 - 500
550 - 600
M24 x 3
580 - 650
800 - 900
900 - 1050
M30 x 3.5
1150 - 1300
1600 - 1800
1850 - 2100 T02-gb
Umbrako Screws and Nuts Grade
10 and 10.8 Thread Size
12 and 12.9 Torque (Nm)
M5 x 0.8
8
11
M6 x 1
14
19
M8 x 1.25
33
45
M10 x 1.5
63
86
M12 x 1.75
111
152
M16 x 2
270
372
M20 x 2.5
521
717 T03-gb
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-1.9-0000
31
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Printed in Germany
32
HYDRAULICS
Printed in Germany
33
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Printed in Germany
34M1.0-0000-00034
HYDRAULICS Hydraulic Symbols
Vented reservoir with lines above the fluid level
M
Electric motor with unidirectional turn and speed
M
Electric motor with unidirectional turn and variable speed
Vented reservoir with lines below the fluid level
Filter or strainer
Hydraulic line with full flow (tubing or hose)
Pilot or drain line or drainage with limited flow
Hydraulic pump with fixed displacement and single direction of turn
Hydraulic motor, bi-directional
Lines crossing; not connected Pressure gauge
Lines crossing and connected
Thermometer Plugged port (test port)
Accumulator gas charged diaphragm type Flow meter
M3559
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-2.0-0000
M1.0-0000-00035 35
HYDRAULICS
Pressure switch
Manual actuator
Double-acting cylinder; unequal area
Spring, (bias to normal deenergised position)
Double-acting cylinder; equal area Solenoid single coil or winding
Single-acting cylinder with spring returned (rod end vented) Hydraulic pilot operated
Single-acting cylinder ram type Solenoid valve, pilot operated
Single-acting cylinder, with cushion Dual solenoid
Assembly housing, manifold block Proportional solenoid
Manual lever actuator
Pilot check valve (pilot to open)
M3560 MS-2.0-0000
36M1.0-0000-00036
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
HYDRAULICS
Throttle, fixed
Shuttle valve
Throttle, adjustable
Single counterbalance valve assembly in manifold Pressure-compensated flow control, fixed
Pressure-compensated flow control with reverse flow bypass; fixed.
Flow divider/combiner
Velocity fuse Bypass flow control with controlled flow, pressure-regulated
Relief valve, fixed setting
Relief valve, adjustable
Check valve
Shut-off valve, manual
P T
T P
Torque generator
L R
Hydraulic steer unit
M3561 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-2.0-0000
M1.0-0000-00037 37
HYDRAULICS
2/2 way valve (two way, two switch positions)
Valve block with 3 operating units
3/2 way valve (three way, two switch positions)
4/2 way valve (four way, two switch positions)
4/3 way valve (four way, two switch positions)
4/3 way valve (four way, two switch positions); manual activation and spring centered
3/2 way valve (three way, two switch positions); Spring bias solenoid control
M3562
MS-2.0-0000
38M1.0-0000-00038
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
HYDRAULICS Hydraulic System Operation The hydraulic unit comprises the motor, pump, tank, all the fllters, valves and the lift cylinder.
Lifting:
The pump supplies oil from the container to the lift cylinder. The lowering valve closes, while the lifting valve opens.
Lowering:The lowering valve opens, the lifting valve closes. Oil flows from the lift cylinder back to the container.
GPC2020/2040/2040S Fork lift cylinder
Filter
Lowering valve
Non-return valve
Overload valve Flow restrictor Pump
Filter
M1988 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-2.1-6620
M1.0-0000-00039 39
HYDRAULICS Platform Lift
Platform lift cylinder Fork lift cylinder
Flow restrictor
Transfer valve
Lowering valve
Filter Overload valve Non-return valve
Flow restrictor Pump
Filter
M1998
MS-2.1-6620
40M1.0-0000-00040
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
HYDRAULICS Fork High Lift
Fork high lift cylinder
Non-return valve
Flow restrictor
Lowering valve Filter Non-return valve Overload valve Flow restrictor Pump Filter
M1999
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-2.1-6620
M1.0-0000-00041 41
HYDRAULICS Platform Lift and Fork High Lift
Fork high lift Platform lift
Flow restrictor
Flow restrictor
Non-return valve
Transfer valve
Filter
Lowering valve
Non-return valve Overload valve Flow restrictor Pump Filter M2000
MS-2.1-6620
42M1.0-0000-00042
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
HYDRAULICS Hydraulic Unit Removal
●
Disconnect the battery.
WARNING
●
Prevent the truck from rolling away.
●
Before carrying out maintenance work place a flat tray or (if necessary) a large cardboard box underneath the work area.
●
Obtain a suitable base onto which you can place the hydraulic unit, e.g. a heavy iron ring.
●
Disconnect all wire connections and the hydraulic unit hoses.
●
Remove the hydraulic unit from the frame.
Depressurise all components before carrying out maintenance work on the hydraulic system. ● Escaping pressurised hydraulic oil can result in serious injuries. ● Any liquid penetrating the skin at high pressure must be considered a serious medical emergency situation, even if the skin does not show any unusual signs at first. The pain will set in later. ● Tighten all connections before pressurising the system again. Keep hands and body away from holes or ports, as this is where hydraulic oil can escape at high pressure. ● To trace leaks, always use a piece of tissue paper, never use your hands.
Pump motor
Pump relay
Hydraulic plate Non-return valve
Solenoid Filler neck
Solenoid
Plug Hydraulic container
MS-6620-001 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-2.2-6620
M1.0-0000-00043 43
HYDRAULICS Replacing the Hydraulic Pump
Replacing the Hydraulic Filter
NOTE
Replacing the Suction Filter The hydraulic pump is not intended to be repaired on site. The pump is a replacement part. All seals on disassembled parts and all filters must be replaced.
●
To replace the filter (30), loosen the screws. Remove the container (1) and O-ring (7) and dispose of the oil according to environmental regulations.
●
Remove the filter (30) and replace it with a new one. Dispose of the filter according to environmental regulations.
Removal ●
●
Remove the hydraulic unit as described in the previous section. Drain the oil via the filler neck.
See diagrams M0473, page M-2.3-2900-002: ●
Remove the screws (10) from the container flange and lift off the container. Remove the O-ring (7).
●
Remove the filter (30) and the suction pipe (31).
●
Undo the screws (29) and remove the pump.
●
Clean all components (except for the motor) with a clean de-greasing agent, remove the used seals and dry all components with compressed air.
Installation ●
Fit a new filter (30) and suction pipe (31).
●
Apply a thin layer of oil to the new seals (20, 21 and 22) and insert them.
●
Insert the coupling (17).
●
Place the pump in position (note alignment) and tighten with the screws (29). Tighten the screws diagonally and evenly.
●
Place the container in position with a new slightly oiled seal (7) and tighten with the screws (10). Tighten the screws diagonally and evenly.
●
Replenish with a suitable hydraulic oil (see Lubricants Table, Chapter 1) and bleed in accordance with the "Start-Up" section.
Replacing the Oil The oil container (volume approx. 1.7 l) does not have an oil drain plug. Used oil must therefore be suctioned off or the oil container must be tipped. Dispose of used oil in accordance with environmental regulations only. To replenish and bleed, refer to the following "Start-Up" section.
Start-Up WARNING Use only approved oils (see Table L01-GB).
●
Check that the system is clean and properly assembled. Above all, the pressure ports must be tight.
●
Fill with hydraulic oil (see Lubricants Table) as far as the lower mark on the filler plug on the container, via a filter with a minimum retention rate of 10 µm.
●
Never run a pump without oil.
●
All components, in particular hydraulic connections, must be completely clean and dry prior to start-up. Otherwise it is impossible to check for leaks.
●
Open the vent screws on the lift cylinders slightly and operate the lifting function several times until no more air escapes. Close the vent screws. Important: the hydraulic container must not be fully emptied during bleeding. If necessary, replenish with hydraulic oil and continue to bleed.
●
Clean the cylinder. Operate the lift function
Fit the hydraulic unit in the reverse order to the Removal section.
Pump motor For maintenance and repair duties refer to Chapter 4.
MS-2.3-6620
44M1.0-0000-00044
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
HYDRAULICS several times and now check the pressure ports and the surrounding hydraulic components for leaks. ●
Park the truck and leave it standing for approx. 20 minutes. Now check the hydraulic oil level and top up if necessary.
M0473 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-2.3-6620
M1.0-0000-00045 45
HYDRAULICS Checking the Valve Settings Checking the Non-Return Valve ●
Raise the forks.
●
Lower the forks, while observing the armature. The armature should not move.
If the armature does move, proceed as follows: ●
Remove the non-return valve (48, Fig. M0473) and replace it with a new one.
Checking the Safety Valve ●
Prepare a test load with 10% more weight than the maximum permissible weight (see data plate).
●
Pick up the load with the forks and operate the lift function.
●
The load should not be raised.
Adjusting the Safety Valve WARNING The safety valve setting is very critical. An incorrect setting can overload the truck and result in severe and even fatal injuries.
●
Prepare two test loads, one with 10% more weight than the maximum permissible load (overload) and one with the maximum truck capacity (normal load).
●
Unscrew the cap (12, Fig. M0473) of the safety valve (14, Fig. M0473).
●
Pick up the overload with the forks and operate the lift function.
●
In the first instance adjust the safety valve (14) so that the overload is not raised.
●
In the second instance pick up the normal load and operate the lift function. The load should be raised.
●
Place the cap with the new O-ring (13) in position and gently tighten it; the setscrew (14) should not twist. Repeat the test. Adjust the setting if necessary.
MS-2.3-6620
46M1.0-0000-00046
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
HYDRAULICS
M0473 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-2.3-6620
M1.0-0000-00047 47
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Printed in Germany
48
DRIVE UNIT
Printed in Germany
49
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Printed in Germany
50M1.0-0000-00050
DRIVE UNIT Drive Unit General 1
The drive unit (see Fig. M0414) is located on the left of the truck behind the cover. It comprises the drive motor (1), live ring bearing (4), transmission (2) and drive wheel (3).
Environmental Protection Observe national and local regulations when handling and disposing of lubricants and cleaning agents.
Drive Wheel
4
Removal ●
Disconnect the battery.
●
Prevent the truck from rolling away.
●
Raise and support the truck. (see chapter 1!)
●
Open the cover.
●
Turn the drive unit until the wheel nuts are accessible.
●
Unscrew the five wheel nuts (4, Fig. M0419).
●
Pull the wheel (5, Fig. M0419) off the stud bolts.
●
Check wheels for wear and damage, replace the drive wheel if necessary.
2 M0414
3
5
Assembly Assembly is the reverse order of removal. Torque the wheel nuts to 130 Nm.
4 M0419
130 Nm
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-3.1-6620
M1.0-0000-00051 51
DRIVE UNIT Drive Unit Removal
●
Remove the drive wheel.
DANGER
●
Turn the tiller as far to the left as possible.
●
Unscrew the oil filler plug.
●
Turn the tiller as far to the right as possible.
●
Place a suitable container underneath the oil drain plug.
Risk of trapping. The drive unit is very heavy. Always secure it with a suitable mechanism when assembling, removing and handling the drive unit to avoid injuries. ●
Disconnect the battery.
●
Prevent the truck from rolling away.
●
Unscrew the oil drain plug (24) and collect the used oil.
●
Raise and support the truck. (see chapter 1!)
●
Remove the drive unit (see "Drive Unit Removal"). Using lifting gear place it securely on a workbench.
●
Unscrew the four mounting bolts (2, Fig. M1154) and remove the drive motor from the rest of the unit.
●
Open the cover.
●
Remove the steering chain.
●
Remove the brake connections.
●
Unscrew the electrical cables from the drive motor.
●
Unscrew the ten mounting bolts (30) and the live ring bearing (29).
●
Attach a suitable device for retaining the drive unit underneath the transmission. Unscrew the mounting bolts (1, Fig. M0414).
●
Remove the chain wheel (28).
●
Remove the drive unit from the truck.
Drive Unit Assembly
Transmission Assembly Assembly is the reverse order of removal.
WARNING
Assembly is the reverse order of removal. Screw in and tighten the mounting bolts (1, Fig. M0414) with sealant 053050-006. ●
Fit the steering chain and adjust the steering (see Steering chapter).
NEW TRANSMISSIONS ARE SUPPLIED WITHOUT OIL. DO NOT FORGET TO ADD OIL. ●
Clean the oil drain plug (24)
●
Screw in the oil drain plug (24) with a new conical nipple and tighten.
●
Add transmission oil (order no. 053051-017). The oil level must reach the thread of the charging plug. For cold store trucks use oil with order no. 53002-009.
●
Screw in the oil filler plug (31) with a new conical nipple and tighten.
●
Fit the drive motor and re-assemble the drive unit (see "Drive Unit Assembly").
Transmission All references to figure numbers in the chapter relate to diagram M0415, page M-3.1-6620-005, unless otherwise stated.
Transmission Removal ●
Disconnect the battery.
●
Prevent the truck from rolling away.
●
Raise and support the truck. (see chapter 1!)
●
Raise and support the truck.
●
Open the panel.
MS-3.1-6620
52M1.0-0000-00052
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
DRIVE UNIT Transmission Repairs We do not recommend carrying out repairs to the transmission. Ensuring a long service life requires many years' experience in transmission design as well as special tools. In general, transmissions should be replaced. If necessary, repairs can be carried out by licenced Crown specialist service teams.
1
All references to figure numbers in the chapter relate to diagram M0415, page 59, unless otherwise stated.
Disassembly
M0414
2
●
Unscrew the ten mounting bolts (30) and remove the live ring bearing (29).
●
Remove the chain wheel (28).
●
Unscrew the nine mounting bolts (26) and remove the transmission cover (25).
●
Unscrew the eight mounting bolts (23) and remove the cover (21).
●
Unscrew the mounting bolt (20) and remove the disk (19).
●
Press out the flange shaft (17) using an appropriate tool.
●
Remove the bevel wheel (11).
●
Unscrew the mounting nut (10).
●
Press out the bevel pinion shaft (6) using an appropriate tool.
●
Press out the bearing rings using an appropriate tool.
●
Remove the radial shaft conical nipple (16).
●
Thoroughly clean the parts, check them for wear and replace if necessary.
Assembly ●
Press in the bearing outer rings of the conical roller bearings (3), (4), (13) using an appropriate tool.
●
Fit the thread protective ring (5).
●
Screw in the oil drain plug (24) with a new conical nipple into the cover and tighten.
●
Fit a new O ring (22) to the cover.
M1154
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-3.1-6620
M1.0-0000-00053 53
DRIVE UNIT ●
●
●
Apply a thin layer of Loctite 307 to the seat of the conical roller bearing (4) on the pinion shaft (6) and press on the conical roller bearing (4) using an appropriate tool.
●
Always adjust the bevel wheel set according to the correct flank position. The tooth ends should not form a straight line.
Attach the spacer (8) and spacer sleeve (7) to the pinion shaft (6).
●
The tooth bearing must always lie on the inside tooth end.
Insert the pinion shaft (6) into the housing (35) from below.
●
The tooth bearing may lie from high (upper tooth edge) to low (lower tooth edge).
●
Fit a second conical roller bearing (4) and spur pinion (9).
●
Screw on the mounting nut (10) and torque to 160 Nm.
●
Screw the wheel nuts (18) into the flange shaft (17) if they were previously removed or if a new flange shaft is being fitted.
●
Basic Rules:
Place the conical roller bearing (3) in its corresponding bearing ring.
●
Coat the outside edge of the radial shaft seal (16) with Loctite 307 and install it.
●
Apply a thin coat of oil to the sealing lip of the radial shaft conical nipple (16).
●
Fit the spacer (12) onto the bevel wheel (11) and press on the conical roller bearing (13) with an appropriate tool.
Correct tooth bearings for bevel pinion inside tooth end
High
Low
High
Low
Correct tooth bearings for bevel wheel inside tooth end M1565-1
●
Place the spacer (15) and spacer bushing (14) onto the flange shaft (17).
To adjust: add and/or remove compensating spacers (15, 12, 8) and alter the bearing pre-tension.
●
Insert the flange shaft (17) into the housing (35) from below.
Figure M1565-1 shows the tolerances for permissible bevel pinion and bevel wheel tooth bearings.
●
Fit the bevel wheel (11) and disk (19).
Checking the Flank Tooth Bearing
●
Insert the screw (20) and then adjust the bevel wheel set.
●
Colour the tooth flanks of the bevel wheel (11) with touch-up paste (trace colour).
●
Turn the bevel wheel a few times in a single direction. The tooth bearing will be a light area (marked black in Fig. 1565-1) on the tooth flanks.
●
Check the tooth bearing. Bring it within the tolerance levels by removing and/or adding spacers (15, 12, 8), (Fig. M1565-1). Torque the screw (20) to max. 300 Nm. The transmission should turn freely without flank play. Record the turning moment! Repeat until the tooth bearing is within the tolerance levels.
Bevel Wheel Set Adjustment WARNING ADJUST WITH CARE. THE BEARING AND SPACER PRE-TENSIONING AFFECTS THE TOOTH BEARING. DO NOT SET THE PRETENSIONING TOO LOW, AS IT AUTOMATICALLY REDUCES IN THE COURSE OF NORMAL OPERATION. The correct setting can be determined from the tooth profile (see Fig. M1565-1).
MS-3.1-6620
54M1.0-0000-00054
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
DRIVE UNIT 30
29
27 28
160 Nm
32
10
25
33 9
34
4
20
See text
31 35
19 11
26 12 13 14 3
23
15
16 17 18
7
26
8 4
24 22
6
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
21
M0415
MS-3.1-6620
M1.0-0000-00055 55
DRIVE UNIT After adjusting the bevel wheel set (20) remove the screw again, apply a thin layer of Delo 187 and torque again to the most recently recorded value. Replace the nut (10) with a new one and torque to 160 Nm. ●
●
●
Coat the O ring (22) of the cover (21) with oil and insert it in the cover. Apply a thin layer of Loctite 307 to the contact surfaces of the housing (35) and the transmission cover (25) and fit the cover. Torque the screws crosswise, applying the standard tightening torque. Allow 2 hours for the sealant to harden out at room temperature.
oil level must reach the thread of the charging plug. For cold store trucks use oil with order no. 53002-009. ●
Screw in the oil filler plug (31) with a new conical nipple and tighten.
Live Ring Bearing Removal ●
Remove the transmission.
●
Unscrew the ten mounting screws (30) and live ring bearing (29).
Fit the ring gear (28) and live ring bearing (29).
WARNING
Assembly Assembly is the reverse order of removal.
ALLOW AT LEAST 2 HOURS FOR THE CONTACT SURFACE AND THREAD SEALANT TO DRY OUT. NOW ADD OIL. ●
Add transmission oil (order no. 053051-017). The oil level must reach the thread of the charging plug. For cold store trucks use oil with order no. 53002-009.
●
Fit the bleed cap (27).
●
Screw in the oil filler plug (31) with a new conical nipple and tighten.
●
After assembly, apply grease, order no. 053002001, to the live ring bearing.
●
Order no. 053002-004 grease must be applied to cold store trucks. This grease must fully replace the existing grease filling of the live ring bearing. Otherwise the steering system will block due to the grease solidifying from the cold. Pump through the system until only new grease emerges, then clean thoroughly.
Oil Change ●
Disconnect the battery.
●
Prevent the truck from rolling away.
●
Raise and support the truck (see page M-1.06620-001)
●
Turn the tiller as far to the left as possible.
●
Unscrew the oil filler plug (31).
●
Turn the tiller as far to the right as possible.
●
Place a suitable container underneath the oil drain plug (24).
●
Unscrew the oil drain plug (24) and collect the oil.
●
Clean the oil drain plug (24)
●
Screw in the oil drain plug (24) with a new conical nipple and tighten.
●
Add transmission oil (order no. 053051-017). The
MS-3.1-6620
56M1.0-0000-00056
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
DRIVE UNIT
30
29
27 28
160 Nm
32
10
25
33 9
34
4
20 see text!
31 35
19 11
26 12 13 14 3
23
15
16 17 18
7
26
8 4
24 22
21
6
M0415 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
M3.1-1720-004
MS-3.1-6620
M1.0-0000-00057 57
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58M1.0-0000-00058
ELECTRICS
Printed in Germany
59
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M1.0-0000-00060 M1.0-0000-00060 60
ELECTRICS Electrics - General Wire Colour Codes The wires used in the truck are colour-coded and numbered according to their function. The first digit or the first two digits indicate the wire colour while the last two digits are counter numbers.
ABBREVIATION
COLOUR
NUMBER
FUNCTION
BLK
Black
0 **
Digital signal
BRN
Brown
1 **
Analog signal
RED
Red
2 **
Positive not connected
ORG
Orange
3 **
+12 V DC conver ter
YEL
Yellow
4 **
Third DC conver ter
GRN
Green
5 **
Negative not connected
BLU
Blue
6 **
Insulated negative
VIO
Violet
7 **
+5 V DC conver ter
GREY
Grey
8 **
Four th DC conver ter
WHT
White
9 **
Various
RED/WHT
Red/White
29 **
Positive connected
GRN/WHT
Green/White
59 **
Negative connected
** Numbers 01 to 99
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
E01-gb
MS-4.0-0000
M1.0-0000-00061 61
ELECTRICS Abbreviations Switch Symbol Abbreviation List * Abbreviation
Component
Abbreviation
Component
K*
Relay
LMS
Limit switch
ACS
Accelerator pedal switch
LOS
Lower switch
AXS
Auxiliary function switch
ORS
Override switch
BRS
Brake switch
POT
Potentiometer
DIS
Direction control switch
RA
Raise potentiometer
DRS
Door switch
RAS
Raise switch
E DS
Emergency Disconnect Switch
REA
Reach potentiometer
EM
Encoder module
RS
Reverse switch
E NC
Encoder
SAS
Reverse safety switch
FS
Forward switch
SDS
Star t switch
HBS
Handbrake switch
SES
Seat switch
HSS
Fast / Slow Travel switch
SSS
Sideshifter switch
HNS
Horn switch
THS
Thermo switch
KYS
Key switch
TLT
Tilt switch
LGS
Light switch
WAS
Walk along switch
* If one of the above abbreviations is used more than once, a number extension will be used, e.g . SV1, SV2 etc.
MS-4.0-0000
62M1.0-0000-00062
E02-gb
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS
Sundry Abbreviations * Abbreviation
Description
Abbreviation
Description
BV(AK)
Battery Voltage after key
M2 (PM)
Pump motor
BDI
Battery discharge indicator
MRC
Controller
BR
Brake
OHGD
Overhead guard display
BWI
Brush wear indicator
P
Pump contactor
CA
Cable connection
PC
Plug connector (fitting JC)
F
Connection field coils
PCB
Printed circuit board
FAN
Fan
SF
Shunt field
FU
Fuse
STI
Steering wheel indicator
HN
Horn
SV
Solenoid valve
IFD
Information display
TB
Terminal board
JC
Jack connector (fitting PC)
TMM
Truck management module
LINE
Line contactor
TT
Hourmeter
M1 (TM)
Traction motor
VMN
Chopper (Negative voltage motor)
* If one of the above abbreviations is used more than once, a number extension will be used, e.g . SV1, SV2etc.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
E03-gb
MS-4.0-0000
M1.0-0000-00063 63
ELECTRICS Other Abbreviations* Abréviation
Désignation
Abréviation
Désignation
GCSR
Gate Closed Switch Right
GCSL
Gate Closed Switch Left
PLS
Platformswitch
TCM
Traction Motor
PS
Pressure Switch
HR
Heater
* If an abbreviation is used more than one time, a index number is added. E.g.PLS1, PLS2 etc. E12-S-GB
Electrical Symbols EUROPE
1 2 3 4 5 6
USA
1 2 3 4 5 6
DESCRIPTION
EUROPE
DESCRIPTION
Wires joining
Hand operated maintained contact
Wires crossing
Solenoid valve
Wire connection
Inductor
Plug / socket
Resistor
Wire strap
Capacitor
Terminal board
Potentiometer
Fuse J
T
Thermal protector
Contact, normally open
Lamp
Contact, normally closed
Horn
Contact double throw
Battery
Operating device
Diode
Operating devices, slow releasing Operating device, slow operating Hand operated push button
Breakdown diode LED Transistor
c
Mechanically actuated
MOSFET
c
Hydraulically actuated
Thyristor
Emergency disconnect
Comparator
c
.
Varistor
U
Assembled unit
NO
USA
Motor armature
. M0056-gb MS-4.0-0000
64M1.0-0000-00064
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Electrical Components DANGER Jack up the truck before carrying out repair work or troubleshooting the electrical system.
Transmitter (POT, FS, RS) The transmitter is manually activated via a rocker switch in the multitask handle head. The transmitter comprises a switch (FS) for forward travel, a switch (RS) for reverse travel, and a potentiometer (POT) which governs the travel speed.
Brake Switch (BRS) The truck is equipped with three brake switches, which interrupt the electrical supply to the brake (BR) and drive motor (TM).
Lift limiting switch (LMS) This LMS1(Standard 2020/2040) switch interrupts the electrical supply to the lifting contactor when maximum lift has been reached. The lift limit switch is located on the right side of the lift cylinder. LMS2, a pressure switch (GPC models 2040 and 2040S (Load-Sensor) only), controls the two-stage brake and is located in the hydraulic unit. The LMS3 switch (steer limit switch 10° left or right, 2040 model only) controls the two-stage brake and interrupts the electrical supply to the drive motor. The switch is mounted below the knuckle. The LMS4 (2040 Platform lift) switch interrupts the electrical supply to the lifting contactor after reaching the maximum lift. The lift limit switch is mounted in the backrest beside the lift cylinder.
Horn Switch (HNS) A buzzer sounds when the horn button is pressed.
BRS1 is activated when the operator's foot is released from the pedal and is underneath the platform sheet.? On the GPC 2040S BRS1 is located in the steering control system safety circuit. It ensures that the steering centres itself after 10 seconds if the switch is not activated. BRS2, is activated by depressing the operator handle (2040 Model, Quick Pick Handle only). BRS3 (2040 Platform lift and Platform/fork lift),traction cut-off switch, is activated as soon as the platform is raised. The switch is mounted in the back rest.
Lift/Lower switches (RAS, LOS) The switch lift RAS1 activates the lift contactor P (in lift mode). The lower switch LOS1 activates the solenoid valve SV1 (in lowering mode). Both switches are located in the tiller arm.
Key Switch (KYS) The key switch directs the battery supply to the traction controller and the battery discharge indicator (BDI).
Emergency Disconnect (EDS) Pulling the battery connector on the red knob at the top of the truck completely disconnects the power supply to the truck.
Fuses (FU) The main circuit is protected with a fuse F1 for travelling. The steering circuit is protected by fuse F2. For cold store turcks a fuse F5 is used on the distribution pannel for the tiller arm heating elements, as well as fuse F6 for the options. The hydraulic system is protected by fuse F3 and the BDI by fuse F4 (see wiring diagram)
For the platform lift option two switches RAS2 & LOS2 are mounted on the platform floor. When the rocker is operated either the pump contactor P or the solenoid valve SV1 is activated. For the forklift option four additional switches RAS3.1/ 3.2 & LOS3.1/3.2 are mounted in the backrest. On the GPC 2040S only two additional switches,RAS BR1 & LOS BR1, are contained in the backrest (right-hand side).
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.0-6620
M1.0-0000-00065 65
ELECTRICS Walk along switch (WAS) The WAS2.1/2.2(Option) switches are mounted on either side of the backrest and control the drive contactors. When the button is pressed the truck travels forward at creep speed (2020 model) and backwards with the 2040 model.
The additional RS switches of the GPC 2040S are for reverse creep mode travel. They are located on the righthand side of the backrest.
The WAS1.1/1.2 (Standard) switches are mounted in the Quick Pic Handle and control the drive contactors. When the buttons are pressed the truck travels forward at creep speed.
GPC2020 PC410
LOS1/RAS1
HNS
FS/RS
PC411
WAS2:1/2 BDI/TT
PC405
KYS PC1:1/2
EDS P
BR
SV1 U1 PC403
LMS1
F/R
MT
FU1/FU3
PC404 BRS1
HN MP
U2 M0370
CA201 CA202 CA203
CA205 CA206
CA204 MS-4.0-0000
66M1.0-0000-00066
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS GPC2040 LOS1/RAS1
PC410
HNS
FS/RS
PC411 PC412
WAS1:1 WAS1:1/2
WAS2:1/2
PC405 PC407 PC406 EDS FU1/FU3 P F/R
BDI/TT KYS BRS2 LMS3 PC1:1/2 BR
SV1 LMS2 U1
MT
PC403
LMS1
PC404 BRS1 HN MP
M0371
U2 CA201
RAS 3:1/3:2
CA205
CA202
PC601/PC602
CA206
CA203
LOS 3:1/3:2 CA204
RAS2 + LOS2
LMS4/PC409
BRS3/PC408
U3
CA207 CA208
SV2 PC417/PC418
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
M0601 MS-4.0-6620
M1.0-0000-00067 67
ELECTRICS permanently lit when the limit is reached and cannot be changed further in this direction.
Programmer
Display
General The optional Curtis PMC programmer allows the user to program, test and troubleshoot the traction controller. The programmer is connected to the impulse controller via a lead. The power supply to the programmer is provided by the controller (Fig. M0031).
The display contains a 4-line LCD display. The display contrast can be changed in the SPECIAL PROGRAM MODE menu. Four lines of a menu are displayed simultaneously. Other lines can be displayed with the SCROLL DISPLAY keys.
Specific menu items to be selected for editing must be in the top line. The selected menu item is highlighted in programming mode by a flashing arrow (=cursor). Only in this position can a parameter be modified or additional information called up.
SCROLL DISPLAY M0031
Connection
The SCROLL DISPLAY keys are used to scroll up and down the menu. The SCROLL DISPLAY arrow keys can either be pressed repeatedly or held down. When one of the keys is held down the display scrolls along with increasing speed until the key is released.
DANGER Jack up the truck before carrying out any work on or troubleshooting the controller. The drive wheel must not come into contact with the ground. When connecting the programmer to the controller no brake switches may be applied until the programmer has read all the data from the controller. The programmer then displays the controller's model number, the date of manufacture and the software version. After this display the programmer will request further input.
A small scroll bar on the left hand side of the display window indicates the position of the four menu items displayed relative to the overall menu. When the scroll bar is at the top border, it indicates the start of the menu. When it is positioned at the bottom border, the end of the menu has been reached. The example shown (Fig. M0032) is taken from the program menu:
Scroll bar
Cursor
Key Description The programmer is operation via a control panel with 8 keys. Three keys are for selecting the function menu (Program, Test, Diagnostics), two keys scroll the window display up and down, and two keys change the setting of the selected parameter. The MORE INFO key provides additional information about the line selected in the three menus. Pressing the MORE INFO key and the PROGRAM or DIAGNOSTICS key at the same time allows you to access the special program menu or the special diagnostic menu (Fig. M0045-1).
M0032
CHANGE SETTING The CHANGE SETTING keys are used to increase or decrease the setting of the selected parameter in the menu. The CHANGE SETTING keys can either be pressed repeatedly or held down. The longer the key is held down, the quicker the parameter setting is changed.
With the exception of SCROLL DISPLAY, all keys are fitted with an LED. If the key is pressed, the LED lights up and displays the menu used. The LED in the CHANGE SETTING keys has a special function. It is
MS-4.4-6620
68M1.0-0000-00068
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS An LED at the top of each key indicates whether the key is active and whether it is possible to change the parameter in this direction. When a parameter is changed the LED on the key remains lit until the maximum setting for this parameter is reached. When the LED goes out, it is no longer possible to change the parameter in this direction.
MORE INFO The MORE INFO key has three functions: ●
To display additional information via the selected menu item.
●
To start certain special functions (e.g. self test).
●
Select the SPECIAL PROGRAM and SPECIAL DIAGNOSTICS menus (if pressed together with the PROGRAM or DIAGNOSTICS key).
Further information on individual parameters is available from all the programmer menus. To rejoin the list, press MORE INFO again.
DISPLAY 4 line LCD display TEST This key changes to test mode. DIAGNOSTIC This key changes to diagnostic mode. CHANGE SETTING The setting selected in the display is increased or reduced.
PROGRAM This key switches to programming mode.
SCROLL DISPLAY Scroll up or down in the display to show and select additional lines. M0045-1
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MORE INFO Pressing this key obtains further information on the contents of the previously selected line. By pressing this and other keys simultaneously you can enter extended modes. MS-4.4-6620
M1.0-0000-00069 69
ELECTRICS TEST
PROGRAM The PROGRAM key engages programming mode (Fig. M0061). The display shows a menu in list form for all adjustable parameters and functions of the controller with their current settings. You can scroll through the list using the SCROLL DISPLAY keys.
Pressing the TEST key engages test mode. The display provides information about the condition of the inputs and outputs as well as the controller temperature in real time. For the list display of the test menu the required menu item does not have to be in the top line of the display. It only has to be visible in the 4 lines shown in the display in order to be read. The SCROLL DISPLAY keys can also be used here for scrolling. The test menu is used for testing after installation and for troubleshooting. Pressing the MORE INFO key while the programmer is in test mode displays additional information, including abbreviations. The parameter required must also be selected and must therefore be in the top line.
M0061
DIAGNOSTIC The MORE INFO key provides an extended display of the selected parameter with a bar graph, the current setting as well as the maximum and minimum settings for this parameter.
Pressing the DIAGNOSTICS key displays any current errors. Pressing the MORE INFO key during diagnostic mode displays any abbreviations which have been written.
Key Combinations Some modes can be entered into through key combinations.
SPECIAL DIAGNOSTIC mode M0033
Parameters can be changed directly in the list display or alternatively in the extended display after pressing the MORE INFO key. Possible settings for a parameter depend on the settings of other parameters. This means that the possible setting range for one parameter depends on the actual setting of another parameter. For example, the controller does not permit the traction current limit to be set lower than the current limit for the safety reverse function. The controller therefore suppresses logical errors. If you try to set the traction current limit lower than the current limit for the safety reverse function, a display message indicates the relationship.
MS-4.4-6620
70M1.0-0000-00070
This mode shows the error history of the controller. It stores all the errors which have occured since the last time the error history was deleted. However, errors are only listed once even if they occured several times.
Note: The maximum and minimum temperatures of the controller can be seen in the test mode menu. To change to the SPECIAL DIAGNOSTICS menu, apply the brake, press and hold down the MORE INFO key and then press DIAGNOSTICS. The LED in the DIAGNOSTICS key lights up as if the programmer were in diagnostic mode. Additional information on the selected item (the first line is always selected) can be displayed via the MORE INFO key. The error history can only be deleted in the SPECIAL PROGRAM mode (see following paragraph).
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS SPECIAL PROGRAM mode Many tasks can be performed in the SPECIAL PROGRAM mode. Most of them are self-explanatory. In the Special Program menu, among other things, a changed setting can be reset to its original setting, controller settings can be copied and then loaded into a new controller and the diagnostic history can be deleted. To change to this mode, first press and hold down the MORE INFO key. Now press the PROGRAM key. The LED in the PROGRAM key lights up as if the programmer were in programming mode. You can distinguish between the two operating modes by looking at the menu items. Selecting a menu item (the first line is always selected) with the SCROLL DISPLAY keys and then pressing the MORE INFO key again opens up a submenu in which you can change the selected function. Pressing the MORE INFO key a second time returns you to the selection menu.
As the programmer power supply comes from the controller the power supply to the controller must not be interrupted. Therefore neither the emergency switch nor the key switch must be pressed. To store the original settings again, scroll to the line "Revert to Previous Settings" in the display window, press MORE INFO and follow the instructions. Note: All previous settings are overwritten.
Programmer Self-Test The programmer is tested via two special test screens. To perform the self-test connect the programmer to the controller while the truck is switched off. Now press the MORE INFO key when the key switch is switched on. Use the SCROLL DISPLAY keys to change the test display. In the first display each LCD segment is switched on, in the second display all letters of the various menus are displayed.
Deleting the Error History Switch the programmer to SPECIAL-PROGRAM mode. Select menu item *Clear Diagnostic History* and press the MORE INFO key for further instructions. Deleting the diagnostic history also deletes the minimum and maximum temperature settings in the test menu.
To test the key operation the LED in the respective key must be lit during the self-test. The self-test is completed by turning off the key switch.
Copying (Cloning) Controller Settings The Special Program menu items - *Save Controller Settings in Programmer* and *Load Programmer Settings into Controller* - enable controllers to be copied. To do this simply program a controller with the required parameters and store the settings in the programmer (*Save Controller Settings in Programmer* ) . Now transfer the program to another controller with the same model number (*Load Programmer Settings into Controller*).
SCROLL DISPLAY
M0046
! " # $ % &'( )*+,-./ 0 1 2 3 4 5 6 7 8 9 : ;<=>? A B C D E F G H I JKLMNO PQRSTUVWXYZ x
Resetting to Original Settings After connecting the programmer to a controller the controller program is read and stored in the programmer memory. During programming it is therefore possible to access the original settings at any time via the Special Program menu, provided the programmer power supply has not been interrupted.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.4-6620
M1.0-0000-00071 71
ELECTRICS Traction Controller Removal / Installation DANGER Jack up the truck before carrying out repairs or troubleshooting the electrical system.
Removal 1.Disconnect the battery. 2. Prevent the truck from rolling away. 3. Raise the truck until the drive wheel can move freely. 4. Open the cover. 5. Discharge the traction controller capacitors: disconnect the battery. Maintain a resistance of 10 - 100 Ohm, 5 W, for a short time on the Batt - and Batt + terminals of the traction controller. 6. Disconnect the plug connection to the traction controller. 7. Remove the four power lead (tag them if necessary). 8. Remove the four mounting screws and detach the impulse controller.
CAUTION ONLY USE THE CONTROLLER WITH A BATTERY WITH SUITABLE VOLTAGE. DO NOT USE RECTIFIERS OR MAINS EQUIPMENT. The battery voltage must be the same as the rated voltage indicated on the controller data plate.
Installation Installation is the reverse order of removal. 1. Apply a thin coat of heat conductivity paste 0053051008 to the contact surface of the traction controller and install the controller. 2. Test the traction controller.
MS-4.4-6620
72M1.0-0000-00072
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Controller Test This test procedure must be carefully completed when the controller has been replaced. Do not operate the vehicle until you have completed this procedure and all steps have tested correctly.
CAUTION JACK UP THE TRUCK SO THAT THE DRIVE WHEEL CAN MOVE FREELY. KEY SWITCH OFF. BRAKE SWITCH OPEN. DIRECTION CONTROL IN NEUTRAL. DURING THE TEST ENSURE THAT NO ONE IS STANDING BEHIND OR IN FRONT OF THE TRUCK 1. Slide open the cover on top of the controller (Model 1207 only).
6. With the brake released, select a direction and operate the throttle. ●
The drive wheel should begin to turn in the selected direction.
If not, verify the wiring to the forward/reverse switches, forward/reverse contactors and motor. The drive wheel speed should proportionally follow the throttle. 7. Press the programmer TEST key. Scroll down the menu to observe the status of the forward, reverse, brake and mode switches. Cycle each switch in turn observing the programmer. Each input should show the correct state on the programmer. 8. Carry out the PMT-Test Refer to page 79 and 80 of this manual to carryout this test. The test checks the controller's fault detection circuitry. This is a safety item!
2. Connect the programmer.
9. Remove the truck from the blocks and operate it in a safe, clear area.
3. Turn the key switch on.
●
●
The programmer should power up.
●
The controller status LED should flash once at regular intervals.
If not, check for continiuity in the key switch circuit and the controller ground (B-). 4. Press the programmer diagnostics key ●
The display should indicate “No faults found”.
The truck should have smooth acceleration and the maximum speed allowed for this truck. Measure the maximum truck speed and correct the controller setting accordingly.
10. Test the plug braking of the vehicle. ●
Truck should brake evenly.
11. Verify that the high pedal disable (HPD) and directional control are adjusted properly. 12. Close the sliding cover of the controller (Model 1207 only).
5. Press the brake pedal to release the brake. ●
The display still should indicate “No faults found”.
●
The controller status LED should still flash once.
If there is a problem, the programmer will display a diagnostic message and the LED will flash a diagnostic code. When the problem has been corrected, it may be necessary to cycle the brake in order to clear the fault code.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.4-6620
M1.0-0000-00073 73
ELECTRICS Traction Controller 1207 and 1214 Settings The following table shows the traction controller settings which can be changed in the field. Although manufacturer and factory settings are indicated by the programmer, they cannot be altered by the service personnel.
Controller Settings 1207 (GPC2020) Parameter
Range
Settings
Units
1
C/L Main
20-250
250
AMPS
2
C/L Plug
20-250
90
AMPS
3
Acceleration rate
0-3
1,2
sec.
5
Low speed
40-100
60
% Tab01-gb
Important: The driving control 1207 requires to set all potentiometers to 0 (zero) if you want to change parameters with the programmer!
Controller Settings 1214 (GPC2040-2040S) Parameter
Range
Settings
Units
1
C/L Main
20-400
360
AMPS
2
C/L Plug
20-400
90
AMPS
3
Acceleration rate
0-3
1,2
sec.
4
Creep speed/min. duty
0-25
8
%
5
Low speed
40-100
45
% Tab02-gb
MS-4.4-6620
74M1.0-0000-00074
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Program Menu Program Menu
Description
M AI N C / L
Main current limit
L / S MAIN C / L
Low speed main current limit
PLUG C / L
Plug current limit
L / PLUG C / L
Low speed plug current limit
EMR REV C / L
Emergency reverse current limit
L / S EMR REV C / L
Low speed emergency reverse current limit
RAMP C / L
Ramp current limit
L / S RAMP C / L
Low speed ramp current limit
ACCEL RATE
Acceleration rate, in seconds
TYPE
Throttle type
RAMPE SHAPE
Rampe shape
CREEP SPEED
Creep speed, as percent of full throttle
LOW SPEED
Low speed, as percent of full throttle
EMR REV SPEED
Emergency reverse speed, as percent of full throttle
SEQUENCING DLY
Sequencing delay, in seconds
VARIABLE PLUG
Throttle variable plug braking: on or off
HIGH PEDAL DIS
High pedal disable (HPD)
SRO
Static return to off (SRO)
ANTI - TIEDOWN
Anti-tiedown: on or off
QUICK START
Quick-star t throttle factor E05-gb-1
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.4-6620
M1.0-0000-00075 75
ELECTRICS Menu TEST Program Menu
Description
FORWARD INPUT
Forward switch: on/off
REVERSE INPUT
Reverse switch: on/off
BRAKE INPUT
Brake switch: on/off
THROTTLE % SPEED IN
EMR. REV INPUT MAIN CONTACTOR
FWD CONTACTOR REV CONTACTOR BATT VOLTAGE HEATSINK °C MAX TEMP °C MIN TEMP °C
Throttle reading, in percent of full Speed switch: on/off Emergency reverse switch: on/off Main contactor: on/off Forward contactor: on/off Reverse contactor: on/off Battery voltage Heatsink temperature Maximum temperature seen * Minimum temperature seen
*Maximum/minimum temperatures recorded since Diagnostic History was last cleared. E05-gb-2
MS-4.4-6620
76M1.0-0000-00076
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Diagnostic and Special Diagnostic Menu Diagnostic and Special Diagnostic Menu
Description
WIRING CHECK
BB wiring check failed
CONT DRVR OC
Contactor driver overcurrent
DIR CONT WELDED
Direction contactor welded
HPD
High-pedal-disable activated
HW FAILSAFE
Hardware failsafe activated
LOW BATTERY VOLTAGE
Low battery voltage (< 16 V)
M - SHORTED
M- output fault
MISSING CONTACTOR
Missing contactor
NO KNOWN FAULTS
No known faults
OVERVOLTAGE
Overvoltage (> 45 V)
SRO
Static-return-to-off acticated
THERMAL CUTBACK
Thermal cutback due to temperature
THROTTLE FAULT 1
Throttle input fault
THROTTLE FAULT 2
Throttle low input fault
RESET ALL SETTINGS
Rever t to original settings
CONT SETTING-> PROG
Save controller settings in programmer
PROG SETTINGS-> CONT
Load programmer settings in controller
CLEAR DIAG HISTORY
Clear diagnostic history memory
CONTRAST ADJUSTMENT
Adjust display contrast
LANGUAGE SELECTION
Select displayed language
PROGRAMMER INFO
Display programmer information
CONTROLLER INFO
Display controller information
E06-gb MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.4-6620
M1.0-0000-00077 77
ELECTRICS Fault Recovery (including recovery from disable) Almost all faults require a cycling of the KSI or brake input to reset the controller and enable operation. The only exceptions are the following.
Fault
Recovery
Anti-tiedown
Release and reapply HSS
Contactor overcurrent
When condition clears
Emergency reverse
BB reapplied or brake cycled
HPD
Lower throttle to below HPD threshold
Overvoltage
When battery voltage drops below overvoltage
SRO
When proper sequence is followed
Thermal cutback
When temperature changes
Throttle fault
Clears when condition gone
Undervoltage
When battery voltage rises above undervoltage E07-gb
MS-4.4-6620
78M1.0-0000-00078
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Test Procedure Pulse Monitor Trip - Test (PMT) In accordance with EU regulations this test must be carried out at least annually. It tests the safety circuitry of the traction controller.
Equipment A test lead > 1.5 mm2, with a 10 amp fuse and an isolated crocodile clip at each end of the lead.
Test Procedure ●
Power down the truck.
●
Jack up the truck so that the drive wheel does not come into contact with the ground (see Chapter 1).
●
Connect the test lead to the battery negative terminal (B- and LD2 (M-).
●
Connect the programmer to the controller.
●
Power up the truck.
●
Press the brake switch.
●
LED - Code * *** (1_3) appears and the display shows the following ALARM
M - F a u lt
M0461
●
Select forward or reverse travel: The drive motor must not start.
The test has now been successfully completed and the traction controller safety circuitry is working correctly.
DANGER A faulty safety circuit in the traction controller can be fatal. If the test is negative, take the truck out of service immediately. Replace the traction controller and then repeat the test. ●
Power down the truck and lower it.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.51-6620
M1.0-0000-00079 79
ELECTRICS PMT- Test Wiring Diagram
Controller
Test Cable M0460-gb
MS-4.51-6620
80M1.0-0000-00080
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS 1207 and 1214 Traction Controllers
●
Overvoltage - low voltage protection.
●
Switching circuits and software identify errors in the travel switching circuit, the MOSFET driver circuit, the MOSFET transistors, the contactor drivers and the contactors.
●
Sequencing monitoring.
●
Spark-free switching of contactors through microprocessor controller contactor drivers.
●
Ramp start function allows truck to start at full power.
General The 1207 programmable impulse controller provides effective control of the travel behaviour of the truck. The truck is driven by a series motor. This provides two variables for controlling the motor output: field voltage and armature voltage.
DANGER Never connect the controller to a battery with a different rated voltage from that indicated on the controller. A greater battery voltage can damage the controller, while the system will not operate with a lower power supply.
Bedienfeld Abdeckhaube Control panel removable panel
Only operate the controller with special traction batteries. Do not connect it to a rectifier or to mains components. Jack up the truck before carrying out repairs or troubleshooting the electrical system. This will prevent the truck from inadvertantly starting if there are wiring faults.
M0024-GB
Fahrsteuerung 1207 1207 Traction Controller
When the key switch has been turned off the capacitors in the controller remain charged for a few minutes. If you are working on the controller during this time first disconnect the controller from the battery (remove the battery connector). Then short-circuit the B+ and B- connection of the power part via a resistance (10 - 100 Ohm, min. 5 W) for a few seconds to discharge the capacitors.
M0062
Operating Features ●
Smooth control and regenerative braking.
●
High degree of efficiency, silent operation due to power MOSFETs and high level of sampling frequency.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
1214 Traction Controller
MS-4.3-6620
M1.0-0000-00081 81
ELECTRICS Functions At this point we shall only explain the key functions of the controller insofar as they aid understanding for service purposes.
Key Switch The key switch input supplies the logic component of the controller with voltage and starts the sequencing diagnostics. Together with the brake input the key switch input releases all the controller logic functions.
Autotest (Watchdog, internal and external) The external autotest prevents the microprocessor from failing completely, including the internal autotest. This independent checking system for the processor meets EC guideline requirements for an additional, independent backup checking system. The external autotest timer switches the controller (and the microprocessor) off if the software no longer generates a specific, periodic signal sequence. This signal sequence is produced only if the microprocessor is operating correctly. If the autotest timer is not periodically reset, it switches the controller off after 150 msec.
Overtemperature In the event of overtemperature in the end limit (85 °C 95 °C) the output current is proportionally reduced as the temperature rises until it reaches zero.
Performance Reduction at Low Voltage If the battery voltage falls below the fixed permissible value, the controller proportionally reduces the output current. This reduces the maximum travel speed (which is dependent on the current). If the battery voltage then exceeds the fixed low voltage level, the controller proportionally increases the output current. The specified performance as a product of current and voltage therefore remains constant.
Error Detection The internal microprocessor automatically monitors the controller operation. As soon as an error is detected, the status LED on the controller flashes an error code. If it is a critical error, the controller switches off. With temporary errors, such as a low voltage error, the error message automatically goes out once the error has been rectified. The automatic error detection system includes:
The external autotest also switches all the contactor drivers off directly and directly blocks the PWM driver signal to the end limit. It can only be reset by turning the key switch off and on again.
●
Contactor coil interrupted / driver short-circuited.
●
Contactor coil driver excess current / contactor coil short circuit
The internal autotest timer must be periodically reset by the software running correctly. If it is not reset the internal timer runs out and the microprocessor is restarted. The microprocessor switches all its outputs off (thereby also switching the controller off) and tries to restart.
●
Contactor tips welded or closed
●
Overvoltage protection
●
Internal power supply error
●
M error (end limit short circuit)
●
Memory test on power up
●
Travel switch error
●
Low voltage reduction
●
Autotest (external)
●
Autotest (internal)
Current Limit Current limit reduces the PWM signal to the controller power part until the motor current falls below the current limit level.
Overvoltage In the event of overvoltage the PWM switches off and opens the contactors. When the permissible voltage has been reached the controller continues to operate.
MS-4.3-6620
82M1.0-0000-00082
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Error Listing
Error Reset
Errors are listed in the controller memory. Multiple occurences of an error are listed as an event. The error listing can be charged into the programmer to be read off. The SPECIAL DIAGNOSTICS menu provides access to the controller error memory.
Almost all errors require the key switch or brake switch input to be switched off and on again to reset the controller and restore operation. The only exceptions to this are the errors listed in Table E17-GB
This stores all the errors which have occured since the last time the diagnostic history was deleted.
Error
Reset
Excess current contactor coil
When normal coil current has been reached
Travel switch start up protection
Take travel switch back to below threshold
Overvoltage
When battery voltage falls below threshold
Directional switch start up protection
After correct power up sequence
Overtemperature
When end limit temperature falls again
Travel switch error
When normal travel switch signal is reached
Low voltage
When battery voltage rises above threshold
All other errors
Apply and release brakes or turn key switch off / on. E17-GB
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.3-6620
M1.0-0000-00083 83
ELECTRICS Maintenance Maintenance of the controller is confined to external cleaning. When carrying out maintenance work, check the listed errors using the programmer.
WARNING The controller operates with high throughputs. Special safety measures are therefore required. ● Only properly trained personnel must carry out maintenance work. ● Use non-fatigue eye protection. ● Do not wear loose clothing. ● Do not wear jewelry. ● Use insulated tools only.
●
Disconnect the battery (= emergency disconnect).
●
Jack up the truck.
●
Discharge the traction controller capacitors by connecting the BATT- and BATT+ connections on the traction controller (the battery must be disconnected!) via a resistance of 10 -100 Ohm, min. 5 Watt.
●
Remove cables.
●
Remove contamination and corrosion from the contact surfaces.
●
Wipe the controller with a clean, damp cloth.
●
Before connecting the cables make sure that the controller is completely dry.
MS-4.3-6620
84M1.0-0000-00084
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS 1207 Control Line Connections
Power Line Connections
●
PC403-2:
Driver output, reverse travel contactor
M-
Output to drive motor armature
●
PC403-3:
Driver output, forward travel contactor
B-
Battery negative connection
●
PC403-5:
3 wire potentiometer, positive
B+
Connection to battery positive and series wound field of the drive motor
●
PC403-6:
3 wire potentiometer, loop A2
Armature and series wound field connection
●
PC403-7:
3 wire potentiometer, negative
●
PC403-11:
Reverse input
●
PC403-12:
Forward input
●
PC403-14:
Speed reduction switch, input
●
PC403-16:
Key switch input
No other contacts are used.
PC403 16
9
8
1 M0025
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.3-6620
M1.0-0000-00085 85
ELECTRICS 1214 Control Line Connections
Power Line Connections
●
PC403-1 key switch input
M-
Output to drive motor armature
●
PC403-2 brake input
B-
Battery negative connection
●
PC403-3 speed reduction switch input
B+
Connection to battery positive and series wound field of the drive motor
●
PC403-10 forward input A2
Armature and series wound field connection
●
PC403-11reverse input
●
PC403-13 travel switch 3 wire potentiometer, positive
●
PC403-14 travel switch potentiometer, negative
●
PC403-15 travel switch 3 wire potentiometer, loop
●
PC403-18 forward contactor driver output
●
PC403-19 reverse contactor driver output
●
All other pins vacant
PC403 P24
P13
P12
P01
M0065
MS-4.3-6620
86M1.0-0000-00086
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS 1207 Control Panel
Status LED
The control panel is located below the removable cover on top of the impulse controller.
In the event of a fault the LED uses a flashing code to indicate the error which has occured. See the LED Codes table.
Setting Potentiometers Diagnostics with Status LED Five potentiometers allow the maximum traction and braking current, the acceleration rate and the maximum slow travel and creep speeds to be set manually. To change one of these parameters using the programmer the corresponding potentiometer must be set to "OFF".
During normal operation the status LED flashes a single pulse approx. once a second. When an error is identified, the status LED flashes a 2-digit code continuously, interspersed by an interval (see LED codes table) until the error is rectified.
Programmer Connection A socket is provided to connect the programmer. The corresponding connecting lead is supplied with the programmer.
Setting potentiometers
MAIN
PLUG
CREEP ACCEL.
CURRENT LIMIT
Status LED
LOW
STATUS
SPEED LIMIT
Programmer connection socket M0026
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.3-6620
M1.0-0000-00087 87
ELECTRICS CONNECTION SIDE OF CONTROLLER 1214 Programmer connector An modular connector is provided for the handheld programmer. The mating cable is supplied with the programmer.
Status LED The LED displays flashing codes to indicate controller status. See table LED codes.
LED Diagnostics During normal operation, with no faults present, the Status LED flashes a single flash at approximately 1 flash/second, with an interval between the codes. If the controller detects a fault, a 2-digit code is flashed continuously until the fault is corrected.
Connector, 24 pole PC403
Programmer connector Status-LED
A2
MB-
B+
M0064
MS-4.3-6620
88M1.0-0000-00088
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Status LED No of Flashes
Display
LED off
❍
no power or defetcive controller
solid on
●
deffective controller t
single flash
★
controller operational, no faults
1-2
★-★★
1-3
1-4
2-1
2-3
2-4
Console Display
Explanation
Possible cause
hardware fail-safe error
controller deffective
M-fault or motor output shor t
1. M-output shor ted to ground 2. Direction contactor not closing 3. Direction contactor not closing fast enough 4. Internal motor shor t to ground
sequencing fault (SRO)
1. Improper sequence of KSI, brake, and direction inputs. 2. WrongSRO type selected. 3. Brake or direction switch circuit open. 4. Sequencing Delay too shor t
THROTTLE FAULT 1
5 kOhm or throttle wiper input faultr
1. Throttle input wire open. 2. Throttle input wire shor ted to ground or B+. 3. Throttle pot defective. 4. Wrong throttle type selected.
★★-★★★
HPD
high-pedal-disable fault (HPD)
1. Improper seq. Of KSI, brake, throttle inputs 2. Wrong HPD type selected. 3. Misadjusted throttle pot.
★★-★★★★
THROTTLE FAULT 2
★-★★★
★-★★★★
★★-★
HW FAILSAFE
M- FAULT
SRO
throttle pot low open shor ted to b+ or B-
1. Pot Low wire open 2. Pot Low wire shor ted 3. Wrong throttle type selected
Flashcode 2-2 not listed (fault in belly button), because the belly button is not used on this truck. E04-gb-1
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.3-6620
M1.0-0000-00089 89
ELECTRICS Status LED N0 of Flashes
Display
LED off
❍
No power or defective controller
LED on
●
Defective controller
1 flash
★
Controller operational, no faults
3-1
★★★-★
CONT DRVR OC
Contactor or shunt driver overcurrent
1. Shorted coil of direction contactor. 2. Shunt field shorted
3-2
★★★-★★
DIR CONT WELDED
Welded contacts of direction contactor
Direction contactor stuck or closed.
3-3
★★★-★★★
3-4
★★★-★★★★
4-1
4-2
★★★★-★
★★★★-★★
4-3
★★★★-★★★
4-4
★★★★-★★★★
Console Display
Explanation
Possible cause
Not used
MISSING CONTACTOR
LOW BATTERY VOLTAGE
OVERVOLTAGE
THERMAL CUTBACK
Contactor or shunt is missing
1. Direction contactor coil is open. 2. Direction contactor is missing. 3. Shunt field open. 4.Wire to shunt or direction contactor broken or not connected.
Low battery voltage
1. Battery Voltage < 16 Volts 2. Corroded battery terminal 3. Loose battery or controller terminal. 1. Battery voltage > rated controller voltage. 2. Vehicle operating with charger attached.
Overvoltage
Thermal cutback
1. Temperature > 85°C or < -25 °C. 2. Excessive load on vehicle. 3. Improper mounting of controller. 4. Operation in extreme environments.
Not used
E04-gb-2
MS-4.3-6620
90M1.0-0000-00090
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS
Page intentionally left blank
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.3-6620
M1.0-0000-00091 91
ELECTRICS DACI-EL Steering Control System The DACI-EL steering control system is an electronic steering system which uses threephase current technology. There is no physical link between the steering wheel and the steered wheel.
X1
U
-
X2
X4 X5 X6 X7
V
+
X8
X9
X3
W
The steering angle is determined via sensors on the steering panel. For safety reasons and to ensure redundancy, 2 incremental transmitters of different makes are used in parallel. The steering control system evaluates the signals from the two transmitters. If the difference between the transmitters exceeds a given threshold, the truck automatically brakes and an error code is generated. The steered drive wheel is adjusted via a steering motor with a sun and planet gear and the steering chain is set to the required rotary angle. The current wheel position (angle and direction) is transmitted to the steering control system via a sensor bearing in the steering motor and an external, mechanically coupled feedback potentiometer.
DANGER MS-6620-028
Disconnect the battery before carrying out any work on the steering control system or relevant components. Even if the steering control system is working perfectly, the steering motor can move without the steering wheel necessarily moving (caused by a delay in the steered wheel being set straight).
Electrical Connections See Figure MS-6620-028.
CAUTION Do not swap the + (positive) and - (negative) connections. This will damage the steering control system, as it is not polarity protected.
Performance Connections + and - terminals: The power supply (battery) is connected to these terminals. The line is protected by a 50 A fuse. Always use the same type and rating when replacing the fuse.
Control Section Connections Bushings X1 to X8 are inputs and outputs of the control section. Bushing X9 is a service connection for factory settings . The control system cannot be programmed in the field.
Steering Control System Error Codes Bushing X2 contains a diagnostic LED. This indicates the most recent error via a series of flashing codes. Any fault which would result in an impermissable movement of the steered wheel or which would prevent the wheel from following the prescribed specification, immediately cuts out the end limit (< 100 ms). In addition to the cut-out the safety system opens, causing the truck to brake. An error in the external safety system (outside of the steering control system) causes the truck to brake. The error is indicated, but the steering control system is not cut out and the truck can be steered. The error can be identified through the number of light impulses counted. The error codes are listed in the following tables.
U, V, W terminals: These are connected to the steering motor.
MS-4.2-6620
92M1.0-0000-00092
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Steering Control System Error Codes Valid for software version: 1.07. 02
DACI-EL Steering Control System Error Codes Error
Watchdog
RAM error
FLASH error
End limit error message
Potentiometer control
Safety circuit
Voltage control
Error No.
Flashing code
-
1:1 pulse / pause ratio 1:1
< 100 ms
-
1:1 pulse / pause ratio 1:3
End limit not actively connected
-
1:1 pulse / pause ratio 3:1
End limit not actively connected
9
10
11
12
9:1
End limit cutout
Possible Cause
Action
Battery voltage less than 60 % of rated voltage.
Charge or replace battery.
Battery voltage more than 130 % of rated voltage.
Check battery voltage. Make sure power lead (+/-) is secured.
Sensor bearings in steering motor or feedback potentiometer faulty, loose or wire broken.
Check sensor bearings or feedback potentiometer. Make sure the sensor bearings are not loose. Check wiring to X3 and X5.
End limit overvoltage.
Check battery voltage. Make sure power lead (+/-) is secured. Check potentiometer. Check wiring to X3.
< 100 ms
10:1
< 100 ms
Feedback potentiometer faulty or wire broken. Potentiometer supply overload (see error no. 12)
11:1
End limit not actively connected
Faulty component in internal safety circuit of steering controller or outside voltage applied to X2.6.
Check CA 711.14 for outside voltages. Replace steering controller.
Transmitter supply overload or faulty component in the voltage generation of the steering controller.
Check feedback potentiometer and sensor bearings in the steering motor. Check both steering sensors. Check wiring to X3, X5, X6 and X7. If no error is detected, replace the unit.
12:1
< 100 ms
E08-GB MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.2-6620
M1.0-0000-00093 93
ELECTRICS Steering Control System Error Codes Valid for software version: 1.07. 02
DACI-EL Steering Control System Error Codes (contd.) Error No.
Flashing code
End limit cutout
Possible Cause
Action
Low voltage
6
6:1
< 100 ms
Battery voltage less than 60% of rated voltage.
Charge or replace battery.
Overvoltage
7
7:1
< 100 ms
Battery voltage in excess of 130% of rated voltage.
Check battery voltage. Make sure power cable (+/-) is secured.
Sensor bearings in steering motor or feedback potentiometer faulty, loose or broken wire.
Check sensor bearing or feedback potentiometer. Make sure sensor bearings are not loose. Check wiring to X3 and X5.
End limit overvoltage
Check battery voltage. Make sure power cable (+/-) is secured. Check potentiometer. Check wiring to X3.
Error
Plausibility control
8
8:1
< 100 ms
End limit error message
9
9:1
< 100 ms
Potentiometer monitoring
Safety system
Voltage monitoring
10
11
12
10:1
< 100 ms
Feedback potentiometer faulty or wire broken. Potentiometer supply overloaded (see error no. 12).
11:1
End limit not actively connected
Faulty component in internal safety system of steering control system or external voltage applied to X2.6
Check CA 711.14 for external voltage. Replace steering control system.
Transmitter supply overloaded or faulty component in the steering control system voltage generation section.
Check feedback potentiometer and sensor bearing in the steering motor. Check both steering sensors. Check wiring to X3, X5, X6 and X7. Replace the unit if no error is detected.
12:1
< 100 ms
E09-GB
MS-4.2-6620
94M1.0-0000-00094
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Steering Control System Error Codes Valid for software version: 1.07. 02
DACI-EL Steering Control System Error Codes (contd.) Error
Redundant digital inputs
Error No.
13
Flashing code
13:1
End limit cutout
Possible Cause
Action Check wiring to X1. Replace distributor boards if possible.
< 100 ms
One of the two supply signals is not present at either X1.1 or X1.3. Possible broken wire, or one of the distributor boards is faulty. Broken wire in the line leading to the RS422 interface card. Or interface card faulty. Or no power supply to interface card.
Check wiring to X6 and X7. Check power supply to interface card. If possible replace interface card if above measures are unsuccessful.
Parameter setting fault.
Replace steering control system.
Parameter setting fault.
Replace steering control system.
Steering control system EEPROM faulty.
Replace steering control system.
Incremental transmitter monitoring
14
14:1
< 100 ms
U/f characteristic curve parameters unrealistic.
15
15:1
< 100 ms
Feedback potentiometer parameters unrealistic.
16
16:1
< 100 ms
Faulty EEPROM
18
18:1
< 100 ms
E11-GB
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.2-6620
M1.0-0000-00095 95
ELECTRICS Steering Control System Error Codes Valid for software version: 1.07. 02
DACI-EL Steering Control System Error Codes (contd.) Error No.
Error
Safety system overvoltage
Safety system interruption
Steering wheel incremental transmitter redundancy
20
21
22
Flashing code
End limit cutout
20:1
End limit not cut-out; control system operational again after switching off and on again.
21:1
22:1
< 100 ms
Possible Cause
Action
A large load current has briefly occured.
Check current consumption of connected consumers and and any freewheeling diodes. Check wiring to X2.
No voltage supply to X2.5.
Check wiring. If possible replace distributor boards.
Faulty sensor ball bearing or faulty encoder. There may be a loose mechanical connection to the encode or sensor ball bearing.
Replace faulty component. Tighten loose connections.
Error nos. 17 and 19 not listed, cannot occur with steering control systems. Error no. 2 not listed, only possible immediately after a new software version has been incorporated.
Replace steering control system. E12-GB
●
Remove the steering control system (6).
Steering Control System Removal / Installation
Installation
DANGER
INFORMATION
Disconnect the battery before carrying out any work on the steering control system or relevant components.
After installing a steering control system other than the one previously used in the truck:
The steering control system is attached to a motherboard by 4 screws (see Fig. M1884). The motherboard also serves to conduct heat.
Carry out a "Teach In" (see chapter 6 "Setting Straight-Ahead Travel with electrical steering") to make sure the tiller is set straight .
Removal ●
Disconnect the battery.
●
Disconnect all plug and terminal connections to the steering control system (6), if necessary mark the wires beforehand.
●
●
Clean the back board of the steering control system and the contact surface for the attachment board with a lint-free cloth.
●
Apply a thin layer of heat conducting paste over the entire back board of the steering control system.
Undo the 4 mounting screws (4) and nuts (7).
MS-4.2-6620
96M1.0-0000-00096
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS ●
Position the steering control system and fix it with the 4 screws (4) and nuts (7). Tighten the screws evenly.
●
Restore the electrical connections.
●
Connect the battery again.
●
Test the operation of the electrical steering. In particular make sure the drive wheel is turning in the right direction.
If it is turning in the wrong direction correct the power cable connections. U, V, W from the steering control system must correspond to U, V, W on the steering motor.
M1884
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.2-6620
M1.0-0000-00097 97
ELECTRICS Distributor Boards General The distributor boards receive all the control signals which are either used to modulate the drivers on the board (horn, pump, brake and lowering valve) or else are passed on directly to the control system. The following table shows which board is used depending on the model. Figures MS-6620-035 to -036 illustrate how the various boards are printed. They can be used as aids to identify the boards.
Driver Board Usage Model
Board Part Number
GPC 2020 Standard
804247-002
The board is only partially printed, the grey areas in Figure MS-6620-036 indicate the non-printed areas.
GPC 2020 Option Walk along function in backrest
804247-001
The board is only partially printed, the grey area in Figure MS-6620-035 indicates the non-printed connector CA712.
GPC 2040 Standard Walk along function in handle (Quick-Pick)
804247-001
The board is only partially printed, the grey area in Figure MS-6620-035 indicates the non-printed connector CA712.
GPC 2040 Option Walk along function in backrest & walk along function in handle
804247-001
The board is only partially printed, the grey area in Figure MS-6620-035 indicates the non-printed connector CA712.
GPC 2040 Option Walk along function in handle and platform lift
804247-001
The board is only partially printed, the grey area in Figure MS-6620-035 indicates the non-printed connector CA712.
GPC 2040S Option Electrical steering
804247-003
The board is fully printed, see Figure MS6620-037.
Comment
E15-GB
MS-4.9-6620
98M1.0-0000-00098
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Board 804247-001
Board 804247-003
MS-6620-035
Board 804247-002
MS-6620-037
The grey areas in the figures indicate the non-printed areas. LEDs D1, D5, D7 and D11 are lit when there is a switch signal at the driver level input: D1 = Horn driver (HN) D5 = Lowering valve 1 driver (SV1) D7 = Pump contactor driver (P) D11 = Brake driver (BRN)
MS-6620-036
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.9-6620
M1.0-0000-00099 99
ELECTRICS Jumper Arrangement and Usage Depending on the truck model and any options, one of the following driver boards will be fitted: 804247-001, 804247-002, or 804247-003. Table E16-GB shows the jumper arrangement as a function of board layout, model and options. Diagrams MS-6620-038 illustrates the position of the jumper of the boards.
Whenever you replace a board, always check: ●
Is it the right board for this truck model? If the part number is no longer legible on the board, identify the board using figures MS-6620-035 to 37 on the previous page.
●
The jumper settings for the new board. The jumpers must be set according to Table E-16GB "Jumper Usage".
After replacing a board test the operation of the truck options (Walk Along, Quick - Pick, ...).
MS-6620-038
MS-4.9-6620
M1.0-0000-000100 100
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Jumper Settings Truck
Part Number
GPC 2020 Standard
804247-002
GPC 2020 Option Walk along in backrest
804247-001
GPC 2040 Standard Quick Pic Handle
804247-001
GPC 2040 Option Quick Pic Handle & Walk Along in Backrest
804247-001
GPC 2040 Option Quick Pic Handle & Man Lift
804247-001
GPC 2040S Option Quick Pic Handle
804247-001
= Jumper set
JP 1
= Jumper not set
JP 2
JP 3
E16-gb
Platform Lift and Combination Another board (part number 804824) is fitted for the platform lift and combination options (combination = platform lift + fork high lift). This board controls solenoid valve SV2. The LED on this board indicates that a control signal is applied and can be used for diagnostic purposes.
FIL
CA208
CA207
B+
CA208
CA207
804824
SV2
B
M0459-neu
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-6620-039
MS-4.9-6620
M1.0-0000-000101 101
ELECTRICS Electrical Steering Option
LED Signalling Board 808191
2 additional boards are fitted for the electrical steering option.
LED "ON"
Input Output
Signal
Signal path
D118
Output
Self-centering request 1
To steering controller
D123
Output
Self-centering request 2
To steering controller
D134
Input
Steering controller heat dissipator over temperature
From steering controller
D140
Input
Steering motor over temperature
From steering controller
D118
D140
D134
CA711
CA713
1
1
D123
E-013-GB
Board 808 191(see Fig. MS-6620-031) connects the steering control system to the distributor boards. It also contains switches to summarise the two overtemperature outputs of the steering control system and provides the Quick-Pick function safety prompt.
806 191
Four LEDs (D118, D123, D134 and D140) indicate any signals applied and can be used for diagnostic purposes (see Table E-013-GB).
MS-6620-031
Board 808 191 Contact Arrangement Board 808191 Contact Arrangement CA713
Signal
CA711
Signal
CA713.1
Power supply +FILR
CA711.1
Auto-centering request 1
CA713.2
V+ steering control system: +24VDC
CA711.2
Auto-centering request 2
CA713.3
Dead man switch
CA711.3
V+ steering control system: +24VDC
CA713.4
Dead man switch inversion
CA711.4
Travel direction 1 request
CA713.5
Quick Pick
CA711.5
Travel direction 2 request
CA713.6
Quick Pick Enable
CA711.6
Steering angle < Limit 1
CA713.7
Travel direction 1
CA711.7
Steering angle < Limit 2
CA713.8
Travel direction 2
CA711.8
Steering control system heat dissipator overtemperature
CA713.9
Safety system (V-) from steering control system
CA711.9
Steering motor over temperature
CA713.10
Safety system (V+) to steering control system
CA711.10
Tiller brake switch 1
CA713.11
Signal to steering angle display
CA711.11
Tiller brake switch 2
CA713.12
Tiller brake switch 1
CA711.12
Tiller brake switch 3
CA713.13
Tiller brake switch 2
CA711.13
Safety system (V+) to steering control system
CA713.14
Tiller brake switch 3
CA711.14
Safety system (V-) from steering control system
CA713.16
GND (UBatt-)
CA711.15
Signal from steering angle display E-014-GB
MS-4.9-6620
M1.0-0000-000102 102
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Board 808 191 Contact Arrangment
+FILR CA713.1 CA713.2
CA711.3 V+
V+
D118
D123
CA713.3 CA711.1 CA713.4 CA711.2 CA713.5
CA713.6 CA711.6 CA711.7 D131
CA713.7
CA711.4 D132
CA711.5
CA713.8 V+
D140
D134
CA711.8 CA713.15 CA711.9 CA713.12
CA711.10
CA713.13
CA711.11
CA713.14
CA711.12
CA713.10 CA713.9
CA711.14
CA713.11
CA711.15
CA713.16
CA711.13
0V (UBatt -)
MS-6620-032
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.9-6620
M1.0-0000-000103 103
ELECTRICS Board 808 197 The second board (part no. 808 197), converts the digital signals received from sensors ENC1 and ENC2 to an RS422 interface. The steering control system is connected to this RS422 interface.
Figure MS-6620-033 illustrates the position of bushings JC714 to JC716. Figure MS-6620-034 shows the pin arrangment where applicable to field measurements.
The steering control system provides the power supply for the interface board.
JC715 1
JC714
1
JC716
1
MS-6620-033
JC714 +5 Vcc
JC714.1
JC714.2 0V
JC715 JC715.1
IC1
JC715.3 JC715.4
JC716 JC716.1 JC716.2
JC714.3 JC714.4 JC714.5 JC714.6 JC714.7 JC714.8 JC714.9 JC714.10
Digitalausgänge
Digitale Eingänge
JC715.2
JC716.3 JC716.4
MS-6620-034
MS-4.9-6620
M1.0-0000-000104 104
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS Contactors DANGER Disconnect the battery before carrying out work on the contactors. Important Only use original Crown contactors as replacements or Crown spare parts for repairs. The contactors are specially designed for the truck.
GPC2020 Travel Contactor Repairs This contactor has fixed contacts which are connected to the cover. As contacts must always be replaced in pairs, you need a complete cover, 2 movable contacts and 2 contact springs for repairs.
Disassembly All references relate to Figure M0041, unless otherwise stated. ●
Loosen the screws (8) and lift them off with the cover (7).
●
Turn the cover over so that the movable contacts are facing upwards (see Fig. MS-6620-029).
●
Using your thumbs gently raise the movable contact. Press the contact spring down, holding it with a flat, small screwdriver, until it slides out of position in the movable contact.
Inspection
●
Lift out the movable contact towards you.
Contacts
●
Relieve the contact spring and remove it.
●
Remove the second contact and contact spring as described above.
Do not change the fitting position, the location or the wiring. If you disassemble a contactor for inspection or repair, you must mark the position of the contacts in respect of each other. It is important that contacts which are already inwrought should be placed together again. Failure to do so will result in additional wear and premature failure.
Contacts can blacken, tarnish and roughen during normal operation. This is normal and it is not necessary to file or polish them. In fact this should be avoided as mechanically adjusted contacts burn very easily. Under certain conditions the silver coating or the contacts can transfer from one contact to another and be deposited there. This is generally recognised as being safe. The contacts must only be replaced when the silver coating has been eroded to the extent that the base metal is visible.
Coils Coils cannot be repaired. Replace any faulty coils if there is no resistance measured between the connections using an ohmmeter.
Springs Replace any springs showing signs of corrosion or which are fading due to overheating. Always replace the complete set, never individual springs. MS-6620-029
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.11-6620
M1.0-0000-000105 105
ELECTRICS Assembly
1
All references relate to Figure M0041, unless otherwise stated. ●
●
●
8 1
Turn the cover over so that the moving contacts are facing upwards (see Fig. MS-6620-029).
1
Put the contact springs into the container in the cover.
8
Press the contact springs down, holding them with a flat, small screwdriver, and push in the movable contact past the springs.
7
●
When the spring seat on the movable contact is above the contact spring, remove the screwdriver.
●
Check that the contact spring has completely passed over the spring seat. 6 6
2
2 1
5
9 4
4
3
M0041
MS-4.11-6620
M1.0-0000-000106 106
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
ELECTRICS ●
Insert the 2nd contact and contact spring as described above.
●
Insert the dowel pins (4) into the coil body (3).
●
Place the insulation (9) onto the coil body (3).
●
Place the shared fixed contact (5) on the dowel pins (4).
●
Place the cover (7) with the previously installed movable contacts on the coil body. Make sure that the spring-loaded actuators for the contacts are completely inserted in the coil body holes. The cover (7) must lie fully flat on the coil body on the coil body when gentle hand pressure is applied.
●
Insert the screws (8) and tighten them evenly in stages starting from the centre.
GPC2040 and GPC2040S Travel Contactor Repairs These contactors have fixed contacts which are connected to the cover. As contacts must always be replaced in pairs, you need a complete cover, 2 movable contacts and 2 contact springs for repairs.
Disassembly
MS-6620-029
Assembly All references relate to Figure M0170, unless otherwise stated. ●
Turn the cover over so that the moving contacts are facing upwards (see Fig. MS-6620-029).
●
Put the contact springs (6) into the container in the cover.
●
Press the contact spring down, holding it with a flat, small screwdriver (see Fig. MS-6620-029) and push in the movable contact past the spring.
●
When the spring seat on the movable contact is above the contact spring, remove the screwdriver.
●
Check that the contact spring has completely passed over the spring seat.
●
Insert the 2nd contact and contact spring as described above.
●
Place both insulating strips (9) on the coil body (3).
●
Place the shared, fixed contact (5) on the insulating strip opposite the attachment bracket of the contactor.
●
Place the actuators (4) with the springs leading on the axles of the movable contacts (2).
All references relate to Figure M0170, unless otherwise stated. ●
Loosen the screws (8) and lift them off with the cover (7).
●
Turn the cover over so that the movable contacts are facing upwards (see Fig. MS-6620-029).
●
Using your thumbs gently raise the movable contact. Press the contact spring down, holding it with a flat, small screwdriver, until it slides out of position in the movable contact.
●
Lift out the movable contact towards you.
●
Relieve the contact spring and remove it.
●
Remove the second contact and contact spring as described above.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-4.11-6620
M1.0-0000-000107 107
ELECTRICS ●
●
Place the coil body (3) plus the insulating strips and the fixed contact on the cover. Make sure that the actuators of the contacts are fully inserted in the coil body holes. Carefully turn the entire contactor so that the cover (7) is facing up. The cover (7) must lie fully flat on the coil body on the coil body when gentle hand pressure is applied.
&
&
Insert the screws (8) and tighten them evenly in stages starting from the centre. %
$ $
#
'
"
!
M0170
MS-4.11-6620
M1.0-0000-000108 108
MS-GPC2000-GB 4/02 • Rev. A • Printed in Germany
BRAKE
Printed in Germany
109
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Printed in Germany
M1.0-0000-000110 M1.0-0000-000110 110
BRAKE Brake
GPC 2020 Brake System For the GPC 2020 a single-stage brake is used.
Operational Description
Coil resistance: 15.2 Ohm
The drive motor contains a drive wheel brake in the form of a disk brake. The brake forms a single unit with the motor shaft. When there is no voltage in the system the brake is applied (truck is braked). The brakes are released electromagnetically. An axial force generated by pressure springs (1, Fig. MS6620-021) acts on the moving anchor disk (2). The rotor (3) with friction lining on both sides also moves axially. The force acting on the anchor disk jams the rotor between the anchor disk and the friction plate (4) and the brake engages. When a constant voltage is applied to the coil (5), a magnetic force acts on the anchor disk (2). This causes the anchor disk (2) to pull against the pressure springs which releases the rotor (3). The brake is released.
5
1
The dust protection ring (6) protects the brake from contamination.
2
3
4
6
MS-6620-021 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-5.0-6620
M1.0-0000-000111 111
BRAKE GPC 2040 Brake System 2040 series trucks use a 2-stage brake system. The second stage only applies for loads in excess of 300 kg (determined via a pressure switch). The resistance values are: Outer coil 10.5 Ohm Inner coil 32.8 Ohm
MS-6620-022
MS-5.6-6620
M1.0-0000-000112 112
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
BRAKE Removal Preparation CAUTION Prevent the brake components from coming into contact with oil or grease. Item numbers in brackets refer to drawing no. M0195-1. ●
Disconnect the battery.
●
Jack up the truck until the drive wheel is free. Support the truck and prevent it from rolling away.
●
Remove the panel.
●
Blow away the brake dust.
●
Remove the brake wiring electrical plug connection (20).
●
Unscrew the three hex. socket screws (3).
●
Remove the magnetic part (7) from the motor, including everything connected to it.
●
Pull the rotor (16) off the hub (15). Do not damage the teeth.
Maintenance and Repairs ●
Measure the thickness of the brake lining disk (16): GPC2020: min. 7.3 mm GPC2040: min. 6.0 mm
●
Unscrew the friction plate (18) from the motor flange. New friction plates are 1.0 mm thick. Replace if necessary.
●
Take the screws (8) out of their respective nuts.
●
Unscrew the banjo bolts (3 off) (17) from the magnetic body.
●
Remove the anchor disk (14).
●
Thoroughly clean and degrease the components.
●
Check the anchor disk (14), friction plate (18) and brake lining (16) for evenness of wear, cracks, scoring and burning. Replace any worn or damaged parts.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
17
17
M0195-1
MS-5.6-6620
M1.0-0000-000113 113
BRAKE ●
Installation Installation is the reverse order of removal. ●
Unscrew the banjo bolts (17, Fig. M0195-1) until they reach a fixed position on the friction plate (18, Fig. M0195-1).
If the thrust pieces (11) and springs (12) have fallen out of the magnetic body (7), refit them: first the springs followed by the thrust pieces.
CAUTION 4 (four) springs must be fitted for GPC 2020 series brakes. ●
Fit the spring (10) and bushing (13) into the magnetic body (7).
●
Place the anchor disk (14) on the magnetic body.
●
Using a medium strength screw lock screw the banjo bolts (17) into the magnetic body until they reach the stop.
●
Insert the screws (8) into the anchor plate so that an all-round gap of at least 1 mm remains between the anchor plate and the magnetic body.
●
Screw in the friction plate (18) on the motor. Note the hole pattern.
●
Push the brake lining disk (16) onto the hub (15). Make sure that the teeth are not damaged.
●
Attach the pre-assembled magnetic body (7) with the hex. socket screws (3) to the motor.
●
Re-fit the electrical plug connection (20).
Air Gap Setting The working air gap between the magnetic body and anchor plate is measured when the truck is braked (brake de-energised). GPC 2020: 0.2 mm All GPC 2040: 0.25 mm
MS-6620-018
●
Torque the hex. socket screws (3, Fig. M0195-1) evenly to 9.5 Nm.
MS-6620-019
●
Using a feeler gauge check the working air gap at several places along the circumference (Fig. MS6620-020). The air gap should be constant all the way round.
●
To increase the air gap, unscrew the banjo bolts slightly (17, Fig. M0195-1). To reduce the air gap screw the banjo bolts (17, Fig. M0195-1) into the magnetic body (7, Fig. M0195-1). Then measure again as described above.
●
When the air gap has been correctly set, torque the hex. socket screws (3, Fig. M0195-1) again to 9.5 Nm.
MS-6620-020
MS-5.6-6620
M1.0-0000-000114 114
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
BRAKE The brake moment can be set individually for the first and second stages. Turning the setting ring (1, Fig. MS6620-017) into the magnetic body increases the first stage moment. Screwing the thread ring (2, Fig. MS6620-016a ) increases the second stage moment. Both stages have fixed settings caused by the nose of the retaining plate (2, Fig. M0083) and the locking screw (1, Fig. M0083). Intermediate settings are not permissible. Set the default settings as per Fig. M0091 for the GPC2020 and Fig. M0083 for the GPC 2040. Now perform a test brake (see next page). The maximum braking distance must be maintained. After the final brake setting has been made fit the inner ring locking screw and the disk so that the disk lies within the housing groove. Secure the screw with a sealant. Secure the outer ring by bending up the nose of the retaining plate into a notch of the outer ring.
7,2 mm
GPC 2020 1.6 t, Brake Default Setting
Brake Moment Setting
M0091
GPC 2040 Standard 2.0 t, Brake Default Setting Outer ring 6.3 mm
1
GPC 2020, Single Stage Brake 1
2 Inner ring 6.6 mm
M0083
GPC 2040 High Lift and Twin Lift 1.0 t, Brake Default Setting MS-6620-017
GPC 2040, Twin Stage Brake
Outer ring 6.3 mm
2
Inner ring 2.8 mm
M0083 MS-6620-016a MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-5.6-6620
M1.0-0000-000115 115
BRAKE Brake Test
GPC 2040 Standard 2.0 t
DANGER
Braking Distance with Max. Load
Only perform brake tests in restricted areas. Do not endanger human life. Tools required: Measuring tape
Braking Distance Setting The brake test should first be performed with maximum load and then with the truck unladen. With the GPC 2040 series first ensure that the load-dependent pressure switch is working before carrying out a brake test. ●
When the truck is at operating temperature and on a level, dry surface, first increase the speed to maximum with the maximum load.
●
At the measuring point suddenly take your foot off the foot switch (= brake).
●
Measure the braking distance from the point where the brakes were applied (= measuring point) to the point where the truck comes to rest.
●
Run-in Brake (min. 150 brakings) ●
1.5 m to 1.7 m
New Brake (max.10 brakings) ●
1.6 m to 1.8 m
Braking Distance with Truck Unladen Run-in Brake (min. 150 brakings) ●
1.85 m to 2.05 m
New Brake (max.10 brakings) ●
2.1 m to 2.2 m
GPC 2040 High Lift and Twin Lift 1.0 t Braking Distance with Max. Load
Repeat the test three times and calculate the mean braking distance.
Run-in Brake (min. 150 brakings)
Repeat the above procedure with the truck unladen.
●
If necessary adjust the brakes (see previous page) until the permissible braking distance is acheived. The drive wheel should not block!
New Brake (max.10 brakings)
GPC 2020 Standard 1.6 t
●
2.2 m to 2.4 m
2.7 m to 2.8 m
Braking Distance with Truck Unladen Run-in Brake (min. 150 brakings)
Braking Distance with Max. Load
●
2.15 m to 2.35 m
Run-in Brake (min. 150 brakings) New Brake (max.10 brakings) ●
1.35 m to 1.55 m ●
2.35 m to 2.55 m
New Brake (max.10 brakings) ●
1.5 m to 1.8 m
Braking Distance with Truck Unladen Run-in Brake (min. 150 brakings) ●
1.1 m to 1.3 m
New Brake (max.10 brakings) ●
1.3 m to 1.5 m
MS-5.6-6620
M1.0-0000-000116 116
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
BRAKE Testing the Load-Dependent Pressure Switch (GPC 2040 only) ●
Remove the cable from the load-dependent pressure switch
●
Connect the multimeter to the pressure switch and set it to the resistance measuring range.
●
The meter should show a resistance of approx. 0 Ohm.
●
Raise a 350 kg load.
●
The meter should not show any resistance value (infinite).
Druckschalter Pressure Switch Interrupteur manométrique
M0086
Kabel Cable Cable
Measuring values: Load raised (switch open): infinite Load not raised: (switch closed): approx. 0 Ohm
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-5.6-6620
M1.0-0000-000117 117
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Printed in Germany
118
STEERING
Printed in Germany
119
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Printed in Germany
M1.0-0000-000120 M1.0-0000-000120 120
STEERING Steering Drive System
●
Check all the bearings and teeth for wear and damage. Replace any worn parts.
●
If you notice any damage to the tooth profile or large metallic items in the oil, you must also carefully replace all the bearings.
DANGER Before carrying out any work on the electrical system: Disconnect the battery to de-energise the truck. Trucks with electrical steering are fitted with a maintenance-free three-phase motor / transmission combination (steering drive). This drive system is connected to the chain pinion on the live ring bearing of the drive unit, via a steering chain. The steering drive transmission system has lifetime lubrication.No oil change is therefore required.
Removing the Motor from the Transmission (see Fig.MS-6620-027, following page) Place the steering drive vertically - with the motor pointing up - in a suitable device. ●
A sensor bearing is integrated within the transmission. It sends a feedback signal to the steering control system.
Clearly tag all the cables so that they can later be re-connected without difficulty. Disconnect the wires from the terminal board (1). Using a Molex tool press the pins out of the AMP housing (2).
CAUTION A temperature sensore integrated in motor coil provides the steering control system with the current motor temperature. The steering control system switches off the motor in the event of thermal overload to prevent the coil from being damaged.
Heavy, loose parts can cause injury. Wear safety shoes. If the 4 tension bolts (3, Fig.MS-6620-027) are removed and the motor taken out of the device, the motor may fall apart and the heavy parts may cause injury.
Steering Drive Removal DANGER Risk of trapping and severing of hands by the steering chain. Make sure the truck cannot be switched on again. The safest way to do this is to disconnect the battery. ●
Remove the chain cover.
●
Loosen the chain tensioner.
●
Remove the steering chain from the steering motor drive pinion.
●
Unscrew the electrical connections from the steering motor (do not forget to tag the cables) and remove the AMP plug.
●
Remove the 4 tension bolts (3).
●
Carefully lift the motor out from the top. Take care not to damage the wires. Maintain the bearing plate (4) in position. Keep the motor vertical (See warning above). Do not damage the rotary shaft seal (5). Place the motor in a suitable device vertically, with the drive facing down.
Replacing the Motor Bearings (see Fig.MS-6620-027, following page)
●
Remove the 4 mounting screws from the steering motor and lift out the steering motor.
●
The rotor is positioned on the side of the bearing plate (4) in a in a deep groove ball bearing (32) and on the drive side in a sensor ball bearing (5). Always replace both bearings, even if only one appears faulty.
Repairing the Steering Drive All repairs made to the steering drive must be carried out in a clean environment, using clean tools. General Rules: ●
Replace all the seals if you are disassembling the drive unit.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-6.2-6620
M1.0-0000-000121 121
STEERING
35 5 6 4
7
3
8 9 10 11
29 34
12
28
33 32 31 2
27
13
26
14
15 30
16 17 18
1
19
20
21
22
23 24 25 MS-6620-027 MS-6.2-6620
M1.0-0000-000122 122
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
STEERING Replacing the ball bearing on the bearing carrier side (see Fig.MS-6620-027): ●
●
Pull on the bearing carrier (4). At the same time pull the rotor (30) off the motor. Do not damage the coils. Warning: The stator is loose. Do not remove the motor from the device or tilt it (see warning in this chapter). Remove the retaining ring (31) from the bearing carrier (4).
●
Pull the bearing carrier (4) off the ball bearing (32). Do not loose the shim (34).
●
●
Repairing the Steering Transmission First disassemble the motor as described in the previous section. The steering transmission is filled with 250 cm3 of transmission liquid grease. Prepare the workplace accordingly to collect the old grease and dispose of it in accordance with environmental regulations. Disassembly (see Fig.MS-6620-027): ●
Remove the sensor bearing (5) and the compensating shim (6) from the bearing seat in the transmission cover.
Remove the shaft retaining ring (33) from the rotor (30) and pull off the ball bearing (32).
●
Clean the seats of the bearings and the shim. Apply a thin coat of oil to the seats of the bearings and the shim.
Rotate the transmission and remove the chain pinion and the key (19), then position the transmission vertically again.
●
Remove the screws (8) and lift off the transmission cover. Do not use any sharp-edged levers as these will damage the contact surfaces of the housing.
●
Take care not to loose the cylinder pin (29).
●
Remove the following in turn: - Bearing (9) - Shim (10) - Gear wheel (11) - Key (13) - Spline (12) and pull both bearings (14) from out of the transmission housing.
●
Remove the drive shaft in full (18, with 17, 15, 26 and 27) from the bearings (24 and 16).
●
Remove in turn on the workbench: - the shaft retaining ring (27) - the gear wheel (26) - the key (17) - the shim (15)
●
Rotate the transmission housing and remove the radial shaft seal (25). Now pull off the bearings (24) and (16). The retaining ring (23) can remain in the housing.
●
Remove the housing seal (20).
●
Remove the shaft seal (28) from the transmission cover.
●
Place a new bearing (32) onto the rotor shaft.
●
Refit the shaft retaining ring (33).
●
Insert the shim (34) into the bearing carrier (4).
●
Place the bearing carrier (4) and the shim (34) onto the bearing (32).
●
Refit the retaining ring (31).
Replacing the Sensor Bearing (see Fig.MS-6620-027): The sensor bearing (5) remains in the transmission cover when the steering motor is removed. As it is a loose bearing, it is easy to replace. ●
Pull the sensor bearing (5) from its seat in the transmission housing.
●
Remove the compensating shim (6).
●
Clean the bearing seat and the compensating shim (6). Apply a thin coat of oil to the seat and shim.
●
Place the compensating shim in the bearing seat.
●
Pull a new O ring (35) onto the sensor bearing.
●
Push the sensor bearing (5) over the outer ring into the bearing seat. Observe the cable routing.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-6.2-6620
M1.0-0000-000123 123
STEERING
35 5 6 4
7
3
8 9 10 11
29 34
12
28
33 32 31 2
27
13
26
14
15 30
16 17 18
1
19
20
21
22
23 24 25 MS-6620-027 MS-6.2-6620
M1.0-0000-000124 124
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
STEERING ●
Check all components for wear, tooth profile damage and recesses. Preserve immediately any re-usable parts in a non-acidic oil. Scrap any faulty parts.
Fill the transmission with 250 cm3 of ESSO S400 transmission liquid grease or SHELL TIVELA Compound A. Spread the grease with a clean spatula including the tooth profiles of the gear wheels to prevent them from running dry.
●
Insert the bearing (9) into the transmission cover.
CAUTION
●
Using a suitable mandrel press a new radial shaft seal (28) into the seat. Apply a thin layer of grease to the sealing lip of the radial shaft seal (use the same type of grease as for the filling).
●
Place a new seal (20) onto the housing and insert the cylinder pin (29) into the hole in the housing.
●
Position the transmission cover so that the secondary shaft (12) can slide into the bearing (9) in the transmission cover and join the transmission cover to the housing.
●
Initially turn the mounting screws (8) manually. Then gently tighten diagonally and finally torque diagonally to 12 Nm.
Now thoroughly clean and de-grease all components. Carefully remove all the remaining parts of the seals, taking care not to damage the contact surfaces.
Fill the transmission only with one of the following types of grease: ESSO S400 liquid transmission grease SHELL TIVELA Compound A Or use equivalent grease with identical or better specifications. Assembly (see Fig. MS-6620-027): ●
Place the bearing (24) in the lower bearing seat of the housing.
●
Using a suitable mandrel press a new radial shaft seal (25) into the seat. Apply a thin layer of grease to the sealing lip of the radial shaft seal (use the same type of grease as for the filling).
●
Place the bearing (16) in the inner bearing seat at the bottom of the housing.
● Place both bearings (14) in the inner bearing seat at the bottom of the housing. ●
Push the drive shaft (18) from below the housing through the radial shaft seal (25) and the two bearings (24,16).
●
Push the shim (15) through the drive shaft (18) onto the bearing (16).
●
Insert the secondary shaft (12) into the bearings (14).
●
Insert the key (17) into the drive shaft (18).
●
Position the gear wheel (26) so that it engages with the teeth of the secondary shaft.
●
Secure the gear wheel (26) with the shaft retaining ring (27).
●
Insert the key (13) in the secondary shaft (12).
●
Place the gear wheel (11) on the secondary shaft (12). Push the shim (10) over the end of the secondary shaft.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-6.2-6620
M1.0-0000-000125 125
STEERING Steering Tiller Tiller and Recuperating Spring Removal (All Models) Two recuperating springs on the rotary axle of the tiller push the tiller upwards. The inner, 90° offset end of the springs is fixed in the longitudinal slot of the rotary axle. The outer, equally 90° offset end pushes the tiller up. For greasing purposes the springs are easily accessible when the tiller knuckle panel has been removed.
WARNUNG RISK OF INJURY FROM PRE-TENSIONED SPRINGS. Do not reach into the area of the rotary axle while the springs are tensioned.
M0465
Before carrying out any work on the tiller attachment: ●
Disconnect the battery.
●
Prevent the truck from rolling away (see Chapter 1)
●
Set the tiller to its highest position.
●
Remove the front panel.
●
Push out the 2 screws from the tiller knuckle and push the cover up.
●
Disconnect the tiller wire harness electrical plug connection from the board. Open the cable binders and remove the strain relief clamp.
●
Hold the pintail (2, Fig. M0465) in position using a face spanner (3, Fig. M0465).
●
Drive out the dowel pin (4, Fig. M0465).
●
Tilt the face spanner (3, Fig. M0465) upwards (anti-clockwise) to relieve the springs.
●
Drive out the pintail (2, Fig. M0466) and collect the guide pulley and springs.
●
Remove the tiller (1, Fig.MS-6620-0026) from the top. Note: With the GPC2040 and 2040S compensating shims (2, Fig.MS-6620-0026) may be fitted between the tiller and tiller knuckle. Make sure that these are not lost during removal.
M0465
1
2
MS-6620-026
MS-6.2-6620
M1.0-0000-000126 126
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
STEERING Tiller and Recuperating Spring Assembly (All Models) ●
Clean the bearing bushing, compensating shims, springs and pintails. Replace any damaged parts. Grease all parts with grease part no. 053002-001. For cold store models use grease part no. 053002-005.
●
Position the tiller and push the compensating shims in between the tiller and tiller bedding until even play is attained.
●
Carefully drive in the pintail a small distance, taking care not to damage the compensating shims. Push both springs and the guide pulley onto the pintail. The inner, 90° offset end of the springs must be inserted into the axle groove.
●
Drive in the pintail fully.
●
Tilt the tiller upwards as far as it will go.
●
Tension the springs by turning the pintail with a face spanner (clockwise) (Fig. M0465-1) until the dowel pin can be inserted into the axle. Tap on the dowel pin.
●
Check the spring tension. The tiller must not fall down. Open the latch and set the tiller to its highest position. It must be maintained in this position by the springs. On the GPC 2040S the springs act solely as a support for lifting the heavy steering panel.
●
Restore the electrical connections. Refit the strain relief clamp. Secure the wire harness with cable binders. Move the tiller from stop to stop while checking the wire harness is free to move. The wire harness must not be strained or chafe against other parts. Finally check the electrical operation of the controls on the tiller / panel. Do not forget the safety reverse switch. Refit the tiller bedding cover.
M0465-1
1
2
MS-6620-026
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-6.2-6620
M1.0-0000-000127 127
STEERING Tiller Adjustment Forward Travel Setting for Mechanical Steering In order for the truck to travel straight ahead, the drive wheel and tiller must be aligned in parallel. ●
Before checking the chain tension jack up the truck and prevent it from accidental lowering. See chapter 1.
●
The steering chain must be correctly tensioned before checking forward travel or making adjustments (35mm play when you press your thumbs on the centre of the front side of the chain).
●
●
Check forward travel. If there is a deviation in the angle of the tiller, loosen the mounting screws (11, Fig. M0200) of the steering shaft on the chain pinion. Turn the tiller to the centre position. Tighten the screws (11) again and check the forward travel again. If necessary, repeat the setting.
17 8
16
15
7 11
14 14
13
14 9
To aid later maintenance work mark the position of the chain pinion in respect of the steering shaft with a waterproof pen.
10 1
12
2 3
M0200
4 5 6
MS-6.2-6620
M1.0-0000-000128 128
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
STEERING Carefully turn the pinion as far as one stop of the potentiometer. Turn back 2.5 turns from the end stop. Release the bracket and check that the potentiometer pinion teeth engage in the teeth on the steering motor pinion. If necessary, re-adjust the bracket.
Forward Travel Setting for Electrical Steering In order for the truck to travel straight ahead, the drive wheel and tiller must be aligned in parallel. ●
Switch on the truck and align the drive wheel approximately straight. Switch off the truck.
●
The feedback potentiometer (1, Fig. M1883-1) must now be set to the central position.
●
Align the pinion straight.
●
Remove connector X8 (see Fig. M1883-1) from the steering control system. Plug in the Teach-In connector (part no. 810615) to connector X8 of the traction control system.
●
Switch on the truck. Activate the deadman switch and wait approx. 3 seconds until the LED on the steering control system (2, Fig. M1883-1) flashes.
●
Switch off the truck.
●
Remove the Teach-In connector from connection X8 of the traction control system. Refit connector X8 (see Fig. M1883-1).
●
Check forward travel.
CAUTION The potentiometer may be physically slightly damaged. Do not turn it beyond the end stops. ●
Gently push away the potentiometer bracket and hold it at such a distance that the pinion on the potentiometer axle can rotate freely.
2
X8
1
M1883-1
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-6.2-6620 MS-6.2-6620 M1.0-0000-000129 129
STEERING Steering Chain Chain Tension Adjustment ●
Switch off the truck and remove the key. Prevent it from being switched on again.
●
Jack up the truck and prevent it from accidental lowering if the steering chain is only accessible from below. See Chapter 1.
DANGER There is a danger that hands may get trapped in the steering chain. Make sure the truck cannot be switched on. The safest way to do this is to disconnect the battery. ●
●
●
●
Remove chain cover (where applicable). The steering chain is correctly tensioned if when you press your thumbs on the centre of the front face of the chain it contracts by 3 - 5mm.
17 8
16
15
7 11
14 14
To adjust the chain tension, loosen the nut (8, Fig. M0200) and push the chain tensioner in the longitudinal slot in the corresponding direction. Now tighten the nut again and check the chain tension. Repeat the adjustment if necessary.
13
Check forward travel. If there is a deviation in the angle of the tiller, loosen the mounting screws (11, Fig. M0200) of the steering shaft on the chain pinion. Turn the tiller to the straight-ahead position. Tighten the screws again (11) and check the forward travel again. If necessary, repeat the setting. To aid later maintenance work mark the position of the chain pinion in respect of the steering shaft with a waterproof pen.
14 9
10 1
12
2 3
M0200
4 5 6 MS-6.2-6620
M1.0-0000-000130 130
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
LIFTING MECHANISM
Printed in Germany
131
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Printed in Germany
M1.0-0000-000132 M1.0-0000-000132 132
MAST 5.Adjust front fork height, desired value 90-3 mm, measuret across the raiser pivot point
Lifting Mechanism
6.Adjust rear fork height at fork heel, desired value 90+3 mm
Lifting mechanism adjustment
7.Is the fork height not within the toleranz, adjust lowering stop and repeat step 5 and 6.
1.Lift forks 2.Preadjust lowering stops to 33mm
8.Tighten lock nut of tension bar and lowering stop bolt.
3.Lower forks completly 4.Loosen lock nut of tension bar
Pos 1 Lowering Stop 33mm Lift Stop
Pos 2
Lift Limit Switch
90-3 90+3
lower
lift Tension Bar Lock Nut
M0074 MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-7.0-6620
M1.0-0000-000133 133 133
MAST Lift Stop Setting ●
Raise the forks.
●
Check the lift height, rated height 150mm unladen.
●
Set the lower stop screws to the maximum lift height of 150 mm (see Fig. M0074, previous page).
●
Fork Carriage Spring
Set the lift limit switch. Loosen the screws items 1 & 2 (Fig. M0074) and move the lift limit switch until for a complete lifting motion from the lowest position the fork carriage stops approx. 1 mm below the stops.
CAUTION M0467
Pre-tensioned fork carriage springs! To avoid injury when disassembling the fork carriage the springs must be carefully hung out and de-tensioned.
150mm
M0082
MS-7.0-6620
134 134 M1.0-0000-000134
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MAST Lift Chains General Lift chains are a vital component of a forklift truck. The chain system is designed to transfer the lifting force in an efficient and reliable manner. The safe operation of the truck depends on careful maintenance and attention to the lift chains. Most complaints about the chain performance are due to lack of maintenance. Highly stressed precision chains require regular maintenance to ensure a long useful life.
Inspection The chain must be inspected every 100 hours for any signs of faults or damage. If this cannot be performed on the truck, the lift chains must be removed. Irrespective of the result of the inspection, the lift chains, detachable chain anchors and anchor bolts must be replaced after max. 6000 service hours or three years, whichever comes first. The inspection should include the following: ●
Wear to the chain and chain elongation.
●
Pitting due to rust or corrosion, in particular on the outer surfaces of the connection plates;
●
Pins turning in or extruding from the outside plates;
●
Loss of freedom of movement
●
Damage to the anchor bolt attachment;
●
Wear and corrosion to the anchor bolt and anchor;
●
Wear between the bolts and the connection plates;
Oil again immediately after inspection (for oil type refer to the lubricants table). The oil acts both as a lubricant and an anti-corrosion agent.
Wear The chain bends as it passes over the chain rollers. This leads to a gradual wearing of the joints. Any slack a chain undergoes during its lifetime is due to wear to the links and the chain plate eyelet.
DANGER When checking for chain wear be sure to measure a part of the chain which passes over the guide pulleys. Never repair chains by cutting out the worn section and replacing it with a new section. If a chain is worn, always replace both lift chains.
Chain wear can be measured with a wear gauge (Crown No. 106440) or a steel tape measure (see Fig. 2271). Before testing the chain slack it is important to tension the lift chain if necessary. For non-detachable lift chains the weight of the fork carriage or mast is sufficient. If the lift chain is detached it must be kept taut during measurement. The chain slack test must cover at least ten links over at least three different points in a section of the chain which always passes over a pulley during operation.
The following sections cover the above items in detail.
WARNING Do not use chemical solvents or steam to clean the chains as the lubricant applied at the factory will be removed from the inner plate surfaces.
Cleaning The chain surface should be cleaned with parafin, a hard bristle brush and lint-free cloth.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-7.5-0000
M1.0-0000-000135 135 135
MAST Chain Tension C
Tension the lift chain until it is already taut without a load. It should not hang loosely when the forks are lowered.
2271
Centre Chain Dimensions (Dimension C in Fig. 2271). If one length exceeds the rated length by more than 3%, the chains must be replaced in pairs. Pattern: Measurement scale A: 19mm division Measurement scale B: 25mm and 16mm division
DANGER If just one of the faults mentioned in this chapter is detected, both chains together with their chain anchors or bolts must be immediately replaced.
Freedom of Movement Each individual chain link must flex freely. Tight joints (Fig. 2775si) increase friction and the chain tension during lifting. Excessive chain tension in turn accelerates material wear.
2775si
Possible causes of stiff joints are as follows: Bent pins or plates;
●
Rusty joints;
●
Peened plate edges.
Chain Anchor and Pulleys In the course of checking the chain system, the chain anchors, chain bolts and pulleys must be checked for wear. On the chain anchor watch out for wear and cracking of the individual fingers. If one of the above problems occurs replace the chain anchor. Pulleys with heavily worn flanges and contact surfaces must be replaced. Worn flanges are due to misalignment. The chain tension and mast roller setting must be checked.
Worn or Missing Plates Generally speaking, material wear is the cause of worn or missing connection plates. The plates near the chain pin hole (Fig. 2774si) can crack after a large number of lifting cycles with heavy loads.
Never repair damaged chains! This can result in fatal accidents!
●
After adjusting, torque the counternut of the chain anchor to the correct value (see chapter 1, Torque Table).
Replace both chains immediately if cracking shows or plates are missing.
Protruding or Turned Chain Pins
2774si
Considerable frictional forces between the connection plates and the pins occur when lifting heavy loads with an insufficient or non-existant film of oil. In extreme cases the frictional torque in the joints can be such that the pins turn and gradually work out of the chain (Fig. 2776si). This can result in chain failure. Turned pins can be rapidly identified if the flat ends are not all pointing in the same direction.
Chains which are bent or whose edges are worn must be replaced immediately.
MS-7.5-0000
136 136 M1.0-0000-000136
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MAST Chains with twisted or protruding pins must be replaced immediately.
Chain Lateral Wear Wear traces along a stretch of the chain on the pin heads and the outer plates indicate misalignment. This can have one of two causes: uneven chain tension or misalignment between the pulleys and the chain anchors.
Uneven Chain Tension ●
2776si
DANGER Never attempt to repair the chain by driving pins back into the chain. This can result in accidents with severe or even fatal injuries if the chain tears. Fit new chains.
When fitting or adjusting the chains make sure that they are evenly charged. If for example the fork heel height or the platform height are changed, the chain anchors must be loosened until both forks touch the ground. Both chains must have equal amounts of air or tension at this point. The lower chain anchor nuts must be tightened by the same number of turns. When the required height has been reached, fix the setting with the top (chain side) lock nut and its respective lock washer.
Misalignment of Lift Components ●
Corrosion The chains used on fork lift trucks are highly stressed precision components. It is particularly important to maintain the original fatigue strength throughout its useful life.
Corrosion considerably reduces the capacity of a lift or roller chain, because corrosion leads to cracking in the side plates.
Misalignment of the chain pinion and the chain due to the wrong number of washers on the mast or a damaged mast or cylinder components can also contribute to wearing of the chain sides. To test whether this is the case, proceed as follows: Place the truck on a horizontal surface in the service station. Support the fork carrigae and detach both ends of the lift chain from the chain anchor and visually inspect the alignment with the anchor slots.
2773si
It is therefore extremely important to protect lift chains from corrosion, both when operating and in storage. The layer of grease applied at the factory is an excellent protection. This factory lubrication is applied through a hot dip galvanizing process which ensures full penetration of all joints. Do not steam clean or degrease chains. After commissioning the chain supplement the factory lubrication through a regular lubrication schedule. Further details on the correct lubrication and adjustments are given in the operating instructions for the particular model and at the end of this chapter.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-7.5-0000
M1.0-0000-000137 137 137
MAST Lift Chain Lubrication Lubrication is the most important factor in lift chain maintenance. It considerably affects the chain's useful life.
A paste mixture of oil and dirt will gather on the chain joints, but they will not wear as fast as they would if they were left to dry, leaving a metal to metal contact between the pins and plates. Note: A lift chain must never be allowed to dry.
Highly stressed chains under constant use cannot last sufficiently long if they are not regularly lubricated within a planned maintenance schedule. As with all contact surfaces, the tensiled steel precision moving parts require a durable lubricant film between the contact surfaces to avoid excessive wear. Maintaining a lubricant film on all the chain surfaces provides the following benefits: ●
Restricts joint wear to a minimum (chain elongation)
●
Avoids corrosion
●
Reduces the risk of chain bolts turning
●
Restricts the danger of chain joints turning in to a minimum
●
Ensures an even movement of the chains and thus reduces noise levels
●
Reduces the chain tension due to less friction in the chain system
In dusty operating conditions the multi-plate chains can be more efficiently lubricated than roller chains. Multi-plate chains consist of several plates. Therefore they provide several paths for the lubricant to reach the chain bolt (see Fig. 2777si) and allow the oil to penetrate to the bearing surface on the chain bolt, even when the chain is dirty. In normal operating conditions the chains should be cleaned and immediately lubricated every 100 service hours.
Lubricant film
Key factors when considering which lubricant to use are as follows: ●
High degree of penetration in the narrowest of gaps
●
Maximum tolerance of pressure and shearing forces before the lubricant film comes off.
●
2777si
Suitability to the operating temperature range, especially important for cold store trucks.
Crown recommends chain oil part no. 053002-007. Use chain oil part no. 053002-008 for cold store trucks. The use of solid lubricants has not proved to be successful. Lubrication intervals depend on the operating conditions and the environment. Trucks parked outdoors, in cold stores or which are subjected to extreme weather conditions must be lubricated more frequently. Dust will gather on oiled chains in dusty environments. However, even in these conditions, regular lubrication can considerably reduce wear.
MS-7.5-0000
138 138 M1.0-0000-000138
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MAST Fork Tine Test
DANGER
General The fork tines (Fig. M0344) must be checked by trained personnel at the specified maintenance intervals (see chapter 1) for cracks, damage and wear. If the forks are used to transport abrasive loads the inspection must be carried out at shorter intervals.
Fork blade Fork hanger
Forks showing signs of cracking, distortion or wear must be de-commissioned. They endanger the life of the operator and other people as well as the general operation of the truck.
Repairs Fork repairs must only be carried out by the manufacturer / qualified personnel. When repairing supporting members always carry out a load test and check for signs of cracking.
Crack Inspection Fork shank
M0344
Curve section
Inspect all fork tine surfaces for signs of cracks (Fig. M0346) and if necessary carry out a non-rupturing crack test (magnetic particle cracking test in accordance with DIN 4113). For upper and lower fork hangers (Fig. M0347) including their fork back attachments check for cracks on the welding seam.
Fork Identification The data plate is on the side of the fork back (Fig. M0345) and comprises the following data: 1
Capacity
2
Load Centre of Gravity
3
Manufacturing Data (Month / Year)
4
Company Logo
5
Manufacturing Site
Cracks
M0346
1
2
900 x 600 304 ... ../.. 5
4
3
M0347
M0345
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
Check fork hanger welding seams for any signs of cracking
MS-7.6-0000
M1.0-0000-000139 139 139
MAST If any cracking is discovered which could affect safety remove the relevant fork.
Verticality Test Check verticality of fork shank (Fig. M0349) and fork tip (Fig.M0350/0351). If the readings illustrated below are exceeded the fork must be taken out of service.
DANGER Never carry out repair welding to surface cracks, damaged or worn parts around the heel of the fork.
≤ 2.5 mm
Fork Blade Warping Measure the angle deflection between the top of the fork blade and the front of the fork shank. If it is more than 91° or less than 88° (Fig. M0352) the fork must be realigned and checked before it can be used again. For measuring procedure see Fig. M0353.
M0349
Fork tip
≤ 2 mm Min. 88° Max. 91° M0350
250 mm
M0352
500 mm ≥ (x - 17 mm) ≤ (x + 8.5 mm) 500 mm Straight edge x M0351
≤ 6.0 mm
M0353
MS-7.6-0000
140 140 M1.0-0000-000140
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MAST Measuring the Fork Tip Width
Fork Stop
If the fork tip width S is less than 1/6 of a (a = fork back width) do not use the fork (Fig. M0355).
Check the stop mechanism (Fig. M0356) on both fork tines. If faults or damage are discovered do not use the fork.
S≥a/6 Stop mechanism
M0355
M0356
Fork Tine Height Difference Check the height of the fork tines in relation to each other (Fig. M0354) if the fork is fixed to the fork carriage. If the difference is greater than 3 % of the fork blade length the fork tines must be correctly aligned. Example: If the length of the fork blade is 1150mm the maximum permissable deviation is approx. 35mm. It is however generally advisable to align the forks if the deviation is more than 10mm.
L
3 % of L Left Fork
M0354
Right Fork
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-7.6-0000
M1.0-0000-000141 141 141
MAST Wear Check for fork blade wear, in particular at the heel. If the width is 90 % or less than the original value, the fork must be taken out of service. Use a caliper (Crown No. 107330) to check for wear (Fig. M0357).
Outside jaws 100% (Fork Shank)
●
Using the caliper, scan the fork blade between the taper and the curved area.
●
If the inner scan point fits 90% over the fork blade (Fig. M0360), the fork must not be used.
Inside jaws 90 % (Fork Blade)
Fork Blade Cross Section M0357
M0360
●
First caliper the outer opening 100% in the central area "a" (Figs. M0358, M0359) of the fork shank.
Caliper here the outer opening
M0358
Fork Back Section
M0359
MS-7.6-0000
142 142 M1.0-0000-000142
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
CYLINDERS
Printed in Germany
143
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Printed in Germany
M1.0-0000-000144 M1.0-0000-000144 144
CYLINDER Cylinders Piston rod
General There are two main types of hydraulic cylinder: ●
Plunger cylinders, and
●
Piston cylinders (double-acting cylinders)
Deflector Guide ring Seal
The main difference between the two types of cylinder lies in their operation as well as the sealing material design.
Guide ring
Plunger Cylinders (single-acting)
Oil
The plunger cylinder (see Fig. M1475) has only one pressurised rod surface. The piston rod enters the cylinder via a single or several guide rings. A rod seal in the cylinder head and a dirt deflector protect the inside of the cylinder and the piston rod from external contamination.
Cylinder tube
The piston rod return movement is actuated either by the net weight of the rod or by the force acting on the piston rod from the load.
M1475
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-8.0-0000
145 145
CYLINDER Piston Cylinder (Double-Acting Cylinder) On a piston cylinder both sides of the piston are pressurised. The piston rod can therefore be moved in either direction by the oil flow. The piston rod can produce different piston areas. This results in different forces and speeds occuring at a constant pressure and flow volume levels. The rod of the piston cylinder has a piston at one end which enters the cylinder through a guide ring and whose piston seals protect the two oil-filled chambers against each other. The cylinder and piston rod are sealed on the outside by a rod seal in the cylinder head. An additional scraper ring protects the rod seal from external contamination. When a piston cylinder is used as a single-acting cylinder it offers reduced operating pressure with the same cylinder tube inside diameter compared with the plunger cylinder, thanks to the larger piston surface. However, the operating speed is reduced at the same flow rate. The de-pressurised side of the cylinder must be bled.
MS-8.0-0000
146 146
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
CYLINDER Single-Acting Cylinder
Piston Seal
Piston
Guide Ring
CylinderHead
Piston Rod Oil
Cylinder Tube
Rod Seal Deflector Ring
Return Flow to Tank
M0822
Double-Acting Cylinder
Piston Seal
Piston
Oil
Cylinder Tube
Guide Ring
Oil
Rod Seal
O Ring
Deflector Ring
Cylinder Head
Piston Rod
M0824
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-8.0-0000
147 147
CYLINDER Cylinder
●
General WARNING
Pay attention also to the condition of the guide rings when reparing the cylinder. You should fully replace ALL seal components, not just ones which are worn or damaged.
Cylinder Removal
Depressurise all components before carrying out maintenance work on the hydraulic system.
The cylinders are attached differently depending on the truck and its functions. However, the following general points apply to removal:
● Escaping pressurised hydraulic oil can result in serious injuries.
●
The fork carriage or the platform must at all times be prevented from falling. It must not be possible for assemblies to fall accidentally.
●
De-pressurise the pump motor and make sure it cannot be switched on again. Jack up the truck to prevent it from starting accidentally and rolling away (see Chapter 1).
●
Using cardboard or similar material protect the piston rods from scratching against openings.
●
Hold down the "lower" switch until the piston rods are fully lowered into the lift cylinders through their own weight.
●
Remove the hydraulic connections to the cylinders. Collect any spilled oil.
●
Remove the cylinder attachment.
●
Lift the cylinder out of the truck.
● Any liquid penetrating the skin at high pressure must be considered a serious medical emergency situation, even if the skin does not show any unusual signs at first. The pain will set in later. ● Tighten all connections before pressurising the system again. Keep hands and body away from holes or ports, as this is where hydraulic oil can escape at high pressure. ● To trace leaks, always use a piece of tissue paper, never use your hands.
Carefully check the cylinder unit before carrying out repairs. To do this, fully extend and retract the cylinder several times. ●
Check the piston rod for nicks, scratches and other damage to the surface.
●
Check the wiper rings for wear and unusual leaks.
●
If there is excess hydraulic oil where the piston rod emerges from the cylinder, this may be caused by a damaged rod seal. Replace the rod seal, making sure that the new seal is installed cleanly and intact.
Replacing the Rod Seal NOTE
●
Minor irregularities on the cylinder rod running surface or on the piston rod can be removed with an aluminium oxide cleaning cloth or a honing tool. Heavily abraded components must be replaced.
●
After checking all the parts, clean the cylinder components in a high grade solvent and then dry with weak compressed air.
●
Apply a thin coat of hydraulic oil before fitting the clean parts and replacement parts.
MS-8.1-6620
148 148
Before fitting a new seal check the seal groove and piston rod (critical seal fitting) for damage. Otherwise more leaks may occur once the seals have been replace. To replace rod seals, use soft metal (or suitable plastic) assembly aids and tools without burrs or sharp edges. Do not use screwdrivers or similar tools as these can damage the seal edges. If the new seal must be guided over sharp edges, cracks or nicks, use appropriate protective devices.
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
CYLINDER Platform Lift Cylinder
M0395
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-8.1-6620
149 149
CYLINDER Free Lift Cylinder
M1832
MS-8.1-6620
150 150
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
CYLINDER Free Lift Cylinder for Platform Lift and Combination
M1830
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
MS-8.1-6620
151 151
Page intentionally left blank
Printed in Germany
152
ELECTRICAL DIAGRAMS
Printed in Germany
153
Page intentionally left blank
Printed in Germany
154
DIAGRAMS Control Circuit 2020
❶
❶ Options: Combi Instrument For walk along see GPC2040
M1890
MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000155 155
DIAGRAMS Driver Board 2020
❶
❷
❷
❷
❶ Options: Combi-Instrument ❷ Pedestrian function only possible with PCB 804247001 M1891 MS/MP-DIA-6620
M1.0-0000-000156 156
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Traction Controller 2020 ❶
❷
❶ PC403 Pin 4, 8, 9, 10 and 13 not used. ❷ Voltage between PC403-6 and PC403-7: Max. speed = 5 V No drive command = 0 V
M1892 MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000157 157
DIAGRAMS Brake and BDI 2020
BRS1 not actuated = brake applied
M1893 MS/MP-DIA-6620
M1.0-0000-000158 158
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Tiller and Pedestrian Function 2020
❶
❶ Option: Walk along in backrest
M1894 MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000159 159
DIAGRAMS Power Lead 2020 24 V
❶ -
+
❷ PC 1 : 2 52050-022 PC 1 : 1
EDS
52050-023 52065-010
52050-027
30
31
MP
+
P -
FU3 / 100 A FU1 / 125 A 52051-023 804435 *
52051-024
804434 *
1 -
2
F/R +
A2 D2 52051-026
M- A2
B+
A1
TM
D1
52051-025 52051-009
U1 B-
❶ Battery ❷ Battery connector * Bus bar
M1895
MS/MP-DIA-6620
M1.0-0000-000160 160
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Options: ❶ Handle heating ❷ Combi Instrument ❸ Walk along (in backrest) ❹ For 150 mm lift (900 mm no LMS1) ❺ Man lift
Overview 2040 ❺
❺
❺
❺
❺ ❺
❺
❶
❹ ❷
❺
❸ ❸
M1896 MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000161 161
DIAGRAMS Driver Board 2040 ❶ ❺ ❷
❼ ❻
❹
❺ ❺ ❺
❺ ❸ ❸ ❼
Options: ❶ Pin numbers in parathensis for F/C only ❷ Combi instrument ❸ With walk along switch in backrest ❹ With fork lift hight 900 mm ❺ With man lift ❻ If man lift: WHT, PC207-1, +BV (AK) ❼ Walk along with power unit forward MS/MP-DIA-6620
M1.0-0000-000162 162
M1897 MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Driver Board 2040/Platform Lift
M1898 MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000163 163
DIAGRAMS Traction Controller 2040 ❶
❷ ❷
❶ PC403: Unused pins not shown. ❷ Voltage between PC403-14 and PC403-15: Max. speed = 5 V No drive command = 0 V
M1899 MS/MP-DIA-6620
M1.0-0000-000164 164
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Brake and Brake Switch 2040
❶
❷
❷
❶ Brake is applied if the switch is not actuated. ❷ Brake is applied if the switch is actuated.
M1900 MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000165 165
DIAGRAMS Lift/Lower and Limit Switch 2040
❸
❶ ❷
❶ ❷
❹
❺
❻
❶Pressed = lower ❷Pressed = lift ❸Pressed = brake released ❹Actuated = lift cut out ❺Pressed = lift ❻Pressed = lower M1901 MS/MP-DIA-6620
M1.0-0000-000166 166
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Tiller: BDI and Pedestrian Function 2040 ❶
❷
❸ ❹ ❶Pin numbers in parathensis only for option F/C ❷Tiller heating ❸Walk along in backrest ❹Walk along with powerunit forward M1902 MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000167 167
DIAGRAMS Power Lead 2040
24 V
❶ -
+
❷ PC 1 : 2 52050-022 PC 1 : 1
EDS
52050-023 52065-002
52050-026
30
31
MP
+
P -
FU3 / 100 A FU1 / 200 A 52051-003 804255 *
52051-004
804256 *
1 -
2
F/R +
D2
804257 *
TM
A2 52051-026
B+
A2 M-
D1
A1
52051-006 52051-007
U1 B❶ Battery ❷ Battery connector * Bus bar
M1903 MS/MP-DIA-6620
M1.0-0000-000168 168
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Overview 2040S
KYS
PC201 CA201 1
CA206
F2 (10A)
1
8
8
2 3 4 5 6 7
2 3 4 5 6 7
B+ (+24V)
PC206 1 8 2
1 8 2
3 4 5
3 4 5
6 7
6 7
12 9 16 10 11 13 14 15
12 9 16 10 11 13 14 15
8
8
7
7
B+ B-
From EDS From Minus Pumpcontactor
PC205
PC411
FS RS
1 2 3 4 5 6
VIO GRAY/PINK GRN YEL GRAY PINK
1 2 3 4 5 6
F4 (2A)
10 11 13 15 14 12
CA205 10 11 13 15 14 12
+24V FIL
R11
JC410 PC410 2907
WAS1:1
1
1
CA204 BLU
9
9
2911
SW LOWER
2914
2915
SW LIFT
2916
SW HORN
2909
2908
4
4
2
8
8
5
5
9 10
9 10
nu 3
3 6 11 12 13 14 15 16
2912
2
7
2
2910
+V +5V out Poto In 0V
7
107 505
BRN
7
7
4
4
JP3
RED/BLU
CA203
PINK
16
16
8
8
5
5
2 1
2 1
WHT/GRN
F5 (2A)
BLK RED WHT/YEL
6
nu 3 6
1 3 2
1 3 2
1 3 2
4 5
4 5
6
6
Distribution Panel PCB 804247-003 CA712
F
1 2 3 10 11 13 14 15
Key IN Brake coil activ High speed enable Forward IN Revers IN Throttle Pot V+ Throttle Pot VThrottle Pot Wiper
18 18 ForwContOut
R
19 19 ReversContOut 20 20 nu
PC404
1 3 2
BRS1
1 3 2
Deadman
1
1
2
2
3
3
4
4
5 6
5 6
2920 2922
LOS
2923
2921 RAS
RS
010 011
009
RS
nu
Lift-Stop
7 8
PC202
1 2 3 4 5 6 7 8
TT
3 nu 6
1 3 2
CA202
F6 (10A)
1 2 3 10 11 13 14 15
4 5 6
7 8
Steer Angle Display
nu 11 nu 12 nu 13 nu 14 nu 15 nu 16
PINK BLU
PC204 4 5 6
WAS1:2 2913
P-Contactor
PC403
COMBI-Instrument
POT & FS/RS
SV 1
HORN
In Out
FILTER
BACKREST
BDI
1 2 3 4 5 6 7 8
Traction Controller
0V TT BDI nu
1 2 3 4 5 6 7 8
Sensor Load
nu +24V
PC719 JC719
Hour-Meter
PC405
nu +BV nu TT
1 2 3 4 5 6 7 8
BR1 Brakecoil BR2 Brakecoil
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
CA713
JC407 PC407
Electric Steering PCB 808191
1 2 3 4
1 2 3 4
ENCODER PCB (2x128 Pulse)
ENC2
1 2 3 4
1 2 3 4
CA716
PC716 RED BLU WHT BLK
+5V In Signal B Signal A 0V in
1
2 3 4 5 6
7 7 8 8 9 9 10 10
2
CA711
9 10 11 12 13 14
3 4 5 6 7 8
15 16
1 2 3 4 5 6 X6
106 503
104 105
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10
X1
X2
X8
PC708
1 2 3 4 5 6
PC702
2902 2903
005
2904 2905 2906 006 007 008
1 2 3 4 5 6 7 8 9 10
PC706 1 2 3 4 5 6
5902
1 PC701
YEL/BRN WHT/GRAY GRAY/BRN WHT/PINK PINK/BRN WHT/BLU
1
2917 2918 2919
PC704 X4 12 3 4 5 6
Steering OK
PC707 BRN/BLU WHT/RED BRN/RED WHT/BLK
1 2 3 4 5 6
SENSOR-Bearing SKF 6204
1 2 3 4 5 6
X7
X9
Steering Controller DACI
X3
1 2 3 4 5 6
B+
B-
U V W
104 105
504 401 003 004
1 2
3 4 5 6
PC710
1 2
3 4 5 6
JC718
RED RED
BLK RED BLU WHT
F
CROWN ColorCode:
ORG
or
4
YEL
ge
5
GRN
gn
6
BLU
bl
7
VIO
vi
8
GRAY
gr
9
WHT
ws
29
RED / WHT
rtws
59
GRN / WHT
gnws
MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
3 FEEDBACK POT X3.4 to B- = 6.9V X3.6 to B- = 3.2V X3.4 to X3.6 = 3.7V X3.5 to B- = 4.6V (right) X3.5 to B- = 4.9V (middle) X3.5 to B- = 5.4V (left)
SENSOR Bearing SKF
rt
3
0V In +15V In Signal A Signal B
br
RED
X4.1 = +15V X4.2 = + 5V X4.4 = + 5V X4.5 = +15V
JC718 1 2 3 4
T
BRN
2
POT has 5 revolutions. If steer wheel is at straight position, POT must be set at 2,5 revolutions
Temp-Sensor
1
3
U V W
sw
Steering Motor
BLK
From Battery MinusPump Contactor
0
50A PC718 1 2 3 4
802 109 507
Sequencial numbering of the wires
From Fuseholder Drive/Pump
ColorCode
e.g.: 2 9 0 4
X4: Supply Voltage for Encoders
PC705
801 108 506
2
JC410.9 to B- : 1V, Steer Wheel left side JC410.9 to B- : 3.9V, Steer Wheel right side
703
1 2 3 4 5 6
PC703
X8.8 to B- : 2V, Steer Wheel left side X8.8 to B- : 7.3V, Steer Wheel right side
402
X5 1 2 3 4 5 6
1 2 3 4 5 6
1
1 2 3 4 5 6
1 2 3 4 5 6
SERVICE Connector
1 2 3 4
1 2 3 4 5 6
1 2 3 4
PC714
1 2 3 4
PC715
CA714
0V In Signal A +5V In Signal B
502 001 701 002
PCB-RS422 Interface
ENC1
CA715
Steer Sensor
PC717
CA717
Brake Switch, Tiller
1 2 3 4
5901
RED BLK WHT
R Temp-Sensor = 2kOhm (between JC710.1 and JC710.2 at 25˚C)
M1906_gb MS/MP-DIA-6620
M1.0-0000-000169 169
1
0
2
13
12
11
10
9
8
7
6
5
4
3
2
LED YELLLOW 5mm
Terminal MiniFit, Jr.
Connector-Housing
Terminals
Connector-Housing
Terminals
Connector-Housing
Connector-Housing
Connector-Housing
Connector-Housing
Connector-Housing
Connector-Housing 6 10 6 6 4 16 4
PC705 PC708 PC710 PC703 PC718 PC711 JC407 male
female
female
6
PC702
10
7
##$ % &' '$ 6
5
4
3
2
1
6
5
4
3
3
1 1 1 1 1 1
803 450-007 803 450-007 803 450-015 803 450-007 803 450-006 1 16 1 3
803 452-006 803 450-002 803 450-010
40
116 858 803 452-002
!
1
803 450-007
803 450-015
Terminals and LED-Connector must be soldered
For PC711
005 BLK 2919 RED/WHT
108 BRN
004 BLK
506 GRN
801 GRAY
003 BLK
4
3
2
/##-() * '
503 GRN
106 BRN
2903 RED/WHT
401 YEL
2918 RED/WHT 2902 RED/WHT
1
008 BLK 2918 RED/WHT
2917 RED/WHT
007 BLK 2917 RED/WHT
006 BLK
2906 RED/WHT
2905 RED/WHT
2904 RED/WHT
5902 GRN/WHT
5901 GRN/WHT
504 GRN
4
3
2
4
2919 RED/WHT
($ ' $' ,) - # ($)*# + ,
1
" !
10
105 BRN
104 BRN
4
10
6
2
PC701
5
2
3
Connector-Housing
4
1
2
TO STEERING CONTROLLER: X3(PC703), X8(PC708), X5(PC705), X4(PC704), X2(PC702), X1(PC701)
4
801 GRAY
5
108 BRN
6
506 GRN
1
104 BRN
2
105 BRN
8
106 BRN
9
503 GREEN
1 401 YELLOW
2
504 GREEN
3
003 BLK
5
004 BLK
1 402 YEL
3
402 YEL
4
703 VIO
6
703 VIO
1 005 BLK
5 2902 RED/WHT
6 2903 RED/WHT
1 5901 GRN/WHT
3
5902 GRN/WHT
5 2904 RED/WHT
6 2905 RED/WHT
7 2906 RED/WHT
8 006 BLK
9 007 BLK
M1.0-0000-000170 170 008 BLK
MS/MP-DIA-6620
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
( % ) . ' # '$
DIAGRAMS
Steering Motor Controller 2040S
M2041_gb
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Steering Sensor Encoder 2040S
PART LIST LIST No Component
Name
Position
Type (m/fem)
Crown No.
Used
1
Connector-Housing
PC715
803 450-006
1
2
Connector-Housing
PC717
062535-006
1
3
Terminal
PC715
female
116 858
4
4
Terminal
PC717
female
062536-001
4
Comments
Mini Universal MATE-N-LOK
mimi universal MATE-N-LOK
PC715 1 2 3 4
PC717 502 GRN
502 GRN
001 BLK
001 BLK
701 VIO
701 VIO
002 BLK
002 BLK
1 2 3 4
M2038_gb MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000171 171
DIAGRAMS PCB Connection Lead 2040S
PART LIST LIST No
Component
1
Connector-Housing
2
Termimal
Name CA712 CA713
Position Type (m/fem) Crown No. 16 female
Used
803452-002
2
803452-006
32
CA712
CA713
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
10
11
11
12
12
13
13
14
14
15
15
16
16
M2036_gb MS/MP-DIA-6620
M1.0-0000-000172 172
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
DIAGRAMS Steering Feedback POT 2040S
PART LIST LIST No
Component
Name
Position
1
Connector
JC718
4
2
POT
POTI
3
Terminals
JC718 1 2 3
802 GRAY
Type (m/fem)
male
CROWN No.
Used
803 450-002
1
808 003-001
1
803 450-010
3
Comments
5-Gang-Poti 5kOhm
802 Gray 1
109 BRN 109 BRN
2
507 GRN
4
507 GRN 3
Connections must be soldered!
M2037_gb MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000173 173
6
BLACK "2"
BLACK "3"
BLACK "4"
GREEN / YEL
PC204.5
PC204.6
PC203.7
PC203.8
803452-005
803448-002
female
BLACK "1"
7
5
5 6
116858
062007-043
female
female
JC719
1
803450-007
5
1
Used
JC719
803450-010
male
Crown No.
PC719
PC204.4
Housing f. 4,8 mm
Terminal
6
PCB 804247-003
Terminal
Fast On 4,8mm
5
Connector-Housing
4
3
Terminal
(List No. 7)
2
Type (m/fem)
803450-003
Name
PC719
6
5
4
GREEN / YEL
3
BLACK "4"
2
1
JC719
BLACK "3"
BLACK "2"
BLACK "1"
6
5
4
3
2
1
PC719
nu
011 BLK
010 BLK
2923 RED/WHT
2922 RED/WHT
2920 RED/WHT
4,8mm FastOn 2921 RED/WHT
Component
4,8mm FastOn 2922 RED/WHT
Connetor-Housing
4,8mm FastOn 2921 RED/WHT
1
4,8mm FastOn 2923 RED/WHT
PART LIST
4,8mm FastOn 009 BLK
M1.0-0000-000174 174 4,8mm FastOn 011 BLK
MS/MP-DIA-6620
LIST No
DIAGRAMS
Backrest Control Cable 2040S
M2035_gb
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
009 BLK
TRACTION BACKWARD 010 BLK
LIft SW
LOWER SW 2920 RED/WHT
MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
) . & +
.
++ - & & + ++ '(++ + &)+
!"
!#
++ - & & + + & .+ - + &)+
!
./(0-12 -13 -.% 0 .% -12 4)5 . 60 )%3 -.%0 .% .% . 6 6/1 )%3
06/1 ./(
6/10-.% 0 . 6 . 60-.% 0 )%3 )%30-.% 0-12
-.%0-12 0./( -.%0./( 0-13
!" # $ $ $
$
!" # $
$
% & ' ' ()% * + ' , '* 8 " ' " 9
4)5 . 60 )%3 .% 6/1 . 6 -.%0 .%
6/10-.% 0 . 6 . 60-.% 0 )%3 )%30-.% 0-12 -.%0-12 0./( -.%0./( 0-13
7 $ ' & ()%
) *+ & , ) + &
$
./(0-12 -13 -.% 0 .% ./( 06/1
-12 )%3
, ++ ) &
!
% & ' (
DIAGRAMS
Tiller Lead 2040S
M2040_gb
MS/MP-DIA-6620
M1.0-0000-000175 175
M1.0-0000-000176 176 MS/MP-DIA-6620
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
+$*
# # $%&'(
# $%&'(
# $%&'(
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Tiller Head Cable 2040S
DIAGRAMS
DIAGRAMS Power Lead 2040S
M2034_gb MS-GPC2000-F 04/02 • Rev. A • Printed in Germany
MS/MP-DIA-6620
M1.0-0000-000177 177
DIAGRAMS Power Lead 2040S
M2001_gb MS/MP-DIA-6620
M1.0-0000-000178 178
MS-GPC2000-F 4/02 • Rev. A • Printed in Germany
HYDRAULIC SCHEMATIC
Printed in Germany
179
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Printed in Germany
M1.0-0000-000180 M1.0-0000-000180 180
HYDRAULICS 2020/2040/2040S
M1988
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
M/P-HYD-6620
M1.0-0000-000181 181 181
HYDRAULICS Platform Lift
M1998
M/P-HYD-6620
M1.0-0000-000182 182 182
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
HYDRAULICS Fork Lift
M1999
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany
M/P-HYD-6620
M1.0-0000-000183 183 183
HYDRAULICS Platform/ Fork Lift
M2000
M/P-HYD-6620
M1.0-0000-000184 184 184
MS-GPC2000-GB 04/02 • Rev. A • Printed in Germany