812571-006 RevB (GPC3000 Service)

GPC3000 SERIES
MAINTENANCE MANUAL
Bestell Nummer: 812571-006

Revision: B • Printed in Germany
This master 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 & Co. KG

– European Headquarter –
Moosacher Str. 52
80809 München
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 2009
CROWN Equipment Corporation
TABLE OF CONTENTS
3
Notes:
4
TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PAGE SERIAL NO. CUT REV.

Symbols and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fork direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Text Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Maintenance and Repair Instructions . . . . . . . . . . . . . . . . . . . 6
Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Parking the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Working on the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Before Starting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Warning and Instruction Decals on the Truck . . . . . . . . . . . . . 6
INTRODUCTION PAGE SERIAL NO. CUT REV.

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Subsequent Attachments and Modifications . . . . . . . . . . . . . 11
Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Contact Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUBRICATION & ADJUSTMENT PAGE SERIAL NO. CUT REV.

Lifting and Jacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the Truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the truck with a crane . . . . . . . . . . . . . . . . . . . . . . . 15
Lifting the truck with a forklift truck . . . . . . . . . . . . . . . . . . . . . 16
Towing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Towing the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Jacking up the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Jacking up the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Taking the Truck out of Service . . . . . . . . . . . . . . . . . . . . . . . . 18
Testing Re-Commissioned Trucks . . . . . . . . . . . . . . . . . . . . . 18
Restoring the Truck to Service . . . . . . . . . . . . . . . . . . . . . . . . 18
Recommended Lubricants and Accessories . . . . . . . . . . . . . 19
Cold Store Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
GPC 3020/40/60 Inspection and Lubrication Points . . . . . . . 25
GPC 3045 Inspection and Lubrication Points . . . . . . . . . . . . 27
GPC 3055 Inspection and Lubrication Points . . . . . . . . . . . . 29
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Standard Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HYDRAULIC SYSTEM PAGE SERIAL NO. CUT REV.

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Hydraulic Lines and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Bleeding the hydraulic system . . . . . . . . . . . . . . . . . . . . . 35
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Replacing relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Testing and adjusting the relief valves . . . . . . . . . . . . . . . . . . 37
RV1 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
RV2 test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Adjusting RV1/RV2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hydraulic unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hydraulic unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.2 kW hydraulic unit disassembly . . . . . . . . . . . . . . . . . . . . . 38
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Start Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 kW hydraulic unit disassembly . . . . . . . . . . . . . . . . . . . . . 41
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Bleeding and Flushing the System . . . . . . . . . . . . . . . . . . . . . 44
Before flushing and bleeding the system . . . . . . . . . . . . . . 44
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
DRIVE UNIT PAGE SERIAL NO. CUT REV.

Changing the Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . 49
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Replacing the shaft seal of the driven shaft . . . . . . . . . . . . . . 52
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Shaft Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removing the driven shaft . . . . . . . . . . . . . . . . . . . . . . . . . 53
Driven shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Drive Wheel and Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Drive Wheel Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Drive Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Replacing the Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Replacing the Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Special Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Drive Transmission Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Repairing the Drive Transmission Unit . . . . . . . . . . . . . . . . . . 58
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
ELECTRICAL SYSTEM PAGE SERIAL NO. CUT REV.

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Wire colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Contact Symbol Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . 66
Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
GPC 3020/40/60 without Platform Lift . . . . . . . . . . . . . . . . . . . 70
GPC 3040/60 with Platform Lift . . . . . . . . . . . . . . . . . . . . . . . . 73
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GPC 3045 with Platform Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 77

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

Repairing the Steer Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Steer Motor Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 135
Steer Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Final task: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
General Maintenance Instructions . . . . . . . . . . . . . . . . . . . . 136
Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 136
1.2 kW Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
2.2 kW Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Controller Safety Test (PMT) . . . . . . . . . . . . . . . . . . . . . . . . . . 141
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Carrying out the PMT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Testing Access 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Testing Access 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
BRAKE SYSTEM PAGE SERIAL NO. CUT REV.

Electromechanical Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Servicing the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Measuring the air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Replacing the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Installing a wear part kit . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Replacing the brake in full . . . . . . . . . . . . . . . . . . . . . . . . 148
STEERING PAGE SERIAL NO. CUT REV.

Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Steering Assembly Components . . . . . . . . . . . . . . . . . . . . . . 154
Steering Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . 154
Steering Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . 154
Final tasks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Repairing the Steering Transmission . . . . . . . . . . . . . . . . . . . 155
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
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Final tasks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
LIFTING MECHANISM PAGE SERIAL NO. CUT REV.

GPC 3020/40/60 Fork Height . . . . . . . . . . . . . . . . . . . . . . . . . 159
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Adjusting the Height of the Lowered Forks . . . . . . . . . . . . . 159
Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Freedom of Movement of Chain Links . . . . . . . . . . . . . . 163
Chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Chain Anchor and Pulleys . . . . . . . . . . . . . . . . . . . . . . . 164
Worn Connection Plates . . . . . . . . . . . . . . . . . . . . . . . . . 164
Protruding or Turned Chain Pins . . . . . . . . . . . . . . . . . . 164
Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Side wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Lift Chain Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Lubrication Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Separating Lift Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Tools and Equipment Required . . . . . . . . . . . . . . . . . . . . 168
Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Checking the Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Crack Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
CYLINDERS PAGE SERIAL NO. CUT REV.

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
For your personal protection . . . . . . . . . . . . . . . . . . . . . . 173
Hydraulic System Repair Instructions . . . . . . . . . . . . . . . . . 173
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Producing extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Protective mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Gasket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Old Gasket Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Large Gasket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Small Gasket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Rod Seal Assembly, Sealing Lip First . . . . . . . . . . . . . . . 177
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Cylinder Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Replacing the Rod Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
PLATFORM PAGE SERIAL NO. CUT REV.

Platform Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
GPC3000
V
TABLE OF CONTENTS
Replacing the Platform Sensors . . . . . . . . . . . . . . . . . . . . . . . 184

Platform Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Platform Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Platform Assembly and Testing the Platform Sensors . . . . . 184
Testing the Platform Sensors via the Analyzer Menu . . . 184
Possible error cause . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
SCHEMATIC DIAGRAMS PAGE SERIAL NO. CUT REV.

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
With Key Switch and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . 190
TCM - Combi AC1 Power Side . . . . . . . . . . . . . . . . . . . . . . . . 191
TCM - Combi AC1 Logic Side . . . . . . . . . . . . . . . . . . . . . . . . . 192
SCM - EPS AC0 Logic Side . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Interface #1 Tiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Interface #2 Backrest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
GPC3045, 3055 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Switch Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Handle Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Display with Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
CAN Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Power Cables GPC 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Harness, Walk Beside Switch . . . . . . . . . . . . . . . . . . . . . . . . . 205
GPC3055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Beside Switch Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
GPC3055 (no PPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
CAN Interface Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
GPC3055 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Lift / Lower Scissors Harness . . . . . . . . . . . . . . . . . . . . . . . . . 209
GPC3040 / 3060, GPC3045 . . . . . . . . . . . . . . . . . . . . . . . . . 209
Scissors RAS - LOS Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
GPC3055 (no PPC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Walk Beside Switch Harness F/C . . . . . . . . . . . . . . . . . . . . . . 211
Microswitch Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Horn Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Horn Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
SAS Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Main Harness GPC 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
X10 Handle Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Display Harness GPC 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Adapter ZAPI Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
BRK Switch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
X10 - Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
GPC 3000 Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
CAN-Tiller Harness Assembly . . . . . . . . . . . . . . . . . . . . . . . . 227
GPC Standard 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Steer Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Walk Beside Switch Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Contact pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Platform Lift Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Backrest Harness #2 Platform Lift . . . . . . . . . . . . . . . . . . . . . 232
Straight Ahead Sensor Assy . . . . . . . . . . . . . . . . . . . . . . . . . . 233
CAN Interface Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
Lift Lower Scissors Harness GPC 3000 . . . . . . . . . . . . . . . . . 235
LMS Harness Scissors Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
GPC3000
VI
TABLE OF CONTENTS
Scissors RAS - LOS Assy GPC 3000 . . . . . . . . . . . . . . . . . . 237

Platform Lift Fork Switch Assembly RAS / LOS 2-5 . . . . . . 238
Backrest Harness #2 Platform / Forks . . . . . . . . . . . . . . . . . 239
Battery Latch Switch (BLS) Assy . . . . . . . . . . . . . . . . . . . . . 240
Adapter Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Walk Beside Switch Harness F/C . . . . . . . . . . . . . . . . . . . . . 242
Heater Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Connection Cable Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
Connection Cable DC / DC Converter . . . . . . . . . . . . . . . . . . 246
DC / DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
HYDRAULIC SCHEMATIC PAGE SERIAL NO. CUT REV.

Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
GPC 3020 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
GPC 3040/3045/3060 without Platform, GPC 3055 . . . . . . . . 256
GPC 3040/3045/3060 with Platform . . . . . . . . . . . . . . . . . . . . 257
GPC3000
VII
VIII
SAFETY
1
Notes:
2
SAFETY
GPC3000
3
SAFETY
GPC3000
4
SAFETY
Symbols and Indicators
Symbols and Indicators General Symbols
Safety Symbols Fork direction

These symbols are used to show the direction of view
The following symbols will help you to assess the risk in a figure. The direction of the forks is used as refe-
to yourself, other people and materials should you fail rence:
to comply with a safety notice:
DANGER
This symbol warns of immediate danger to the life and
health of personnel.
Severe injury or death will result.
Follow all instructions indicated by this symbol in order
to avoid injury or death.
WARNING
This symbol warns of immediate danger to the health
of personnel. General Text Indicators
Severe injury or death may result.
Follow all instructions indicated by this symbol in order 1., 2., 3. denote work steps to be taken.
to avoid injury or death. 1, 2, 3 etc. indicate item numbers in illustrations.
• denotes lists.
CAUTION
This symbol warns of possible danger to the health of
personnel.
Injury may result.
Follow all instructions indicated by this symbol in order
to avoid injury.
NOTE
This heading warns of material damage and indicates
additional information.
GPC3000
5
SAFETY
General Safety Instructions
General Safety Instructions • Truck modifications and additions may only be per-
formed with Crown’s prior written approval.
Maintenance and Repair Instruc- • The reliability, safety and suitability of Crown trucks
tions can only be ensured by using original Crown parts.
Before Parking the Truck

DANGER
• Brake until the truck comes to rest.
Observe the safety instructions contained in the main-
tenance manual, the operator manual and on the truck. • Lower the fork carriage fully.
Failure to do so could result in serious or even fatal
injuries to maintenance and other personnel. • Apply the parking brake.
Motorised trucks can become hazardous if mainte- • Switch off the truck and remove the key.
nance and servicing work are neglected. Maintenance
and repairs must therefore be carried out in short inter- • When parking on a slope or incline always chock
vals. Appropriate safety guidelines, qualified and all wheels.
trained staff are basic requirements for avoiding risks.
Before Working on the Truck

Maintenance and Repair
• Jack up the truck so that the drive wheel is clear of
• Work must be performed in accordance with these
the ground. Apply the Emergency power discon-
service instructions and relevant service bulletins. nect switch and disconnect the battery.
• Only qualified and authorized personnel may carry • Prevent the truck from rolling away and lowering.
out work on the truck.
• When working on the mast, fork carriage or lifting
• Keep fire protection equipment at hand and do not
mast always apply a chock to prevent accidental
use a naked flame to check fluid levels or to test for lowering.
leaks.
• Allow sufficient room for manoeuvre when testing
• Use groundwater neutral, non-flammable solvents
the truck, to avoid endangering yourself and other
for cleaning. Always perform cleaning work over an people.
oil separator. Protect the electrical system against
damp.
Before Starting the Truck
• Keep the work place and battery charging station
clean, dry and well ventilated. • Test the safety mechanisms.
• Do not allow oils to penetrate the ground or the • Get into the travel position.
drain system. Used oil must be recycled correctly.
Oil filters and dehumidifying inserts must be • Test the lifting mechanism, travel switch, speed
treated as special waste. Observe the local author- control, steering, warning mechanism and brakes.
ity regulations.
• Immediately neutralize and thoroughly rinse any Warning and Instruction Decals on
spilled battery fluid. the Truck
• Keep the truck clean. This will facilitate tracing In the course of periodic maintenance work, check that
loose or faulty components. the warning and instruction decals on the truck are
complete and legible.
• Maintain the legibility of the data capacity plate and
data plate, warning and instruction decals. • Clean any dirty decals.
GPC3000
6
SAFETY
General Safety Instructions
• Replace any faulty or missing decals.

The spare parts manual gives details of the labelling
and arrangement of the warning and instruction decals
on the truck.
GPC3000
7
Notes:
8
INTRODUCTION
9
Notes:
10
INTRODUCTION
General
General Using the Manual
NOTE
Section Table of Contents
This manual is intended only for trained, specialist per-
sonnel who are authorised to carry out the tasks de- IDX Table of Contents
scribed.?? MA Safety
ITD Introduction
Service training
1 Lubrication & Adjustment
Crown offers appropriate truck-related training for serv-
2 Hydraulic System
ice personnel. Ask for details.
3 Drive Unit
Replacement Parts 4 Electrical System
This manual does not contain a spare parts list. Re- 5 Brake System
placement parts can be found in the spare parts cata- 6 Steering
log.
7 Lifting Mechanism
8 Cylinders
Subsequent Attachments and Modi-
fications 9 Platform
10 Glossary
DANGER
Contact Address
Untested modifications can lead to fatal accidents. :
Any modification which alters the original condition of

CROWN Gabelstapler GmbH & Co.KG
the truck requires prior testing and approval in writing
Moosacher Str. 52
by Crown (see contact address).
80809 Munich
• The weight and position of attachments can have a GERMANY
significant affect on the capacity and other features
of the truck. Tel.: +49 (0)89 / 93 002 -0
• Modifications to the electrical system or the subse- Fax: +49 (0)89 / 93 002 -175 or 133
quent installation of electric-poweredcomponents
can damage the truck.
GPC3000
11
INTRODUCTION
Models
Models
The manual covers maintenance and repair work for
the following models:
:
GPC 3020
GPC 3040
GPC 3060
GPC 3045
GPC 3055
GPC3000
12
LUBRICATION & ADJUSTMENT
13
Notes:
14
Lifting and Jacking
Lifting and Jacking
WARNING
Scalding hazard
Charged batteries are dangerous. The transport of
charged batteries is governed by special regula-
tions.
Failure to comply with safety regulations can result in
serious personal injury and damage to the transported
goods.
• Follow the national and international regulations
concerning the transport of acid-filled batteries.
• Contact your freight company for details of relevant
shipping conditions.
GPC840
CAUTION
Scalding hazard
• You must remove the battery before transporting
the truck.
This will prevent possible leakage of battery acid in the
truck and resulting material or personal damage.
Lifting the Truck
DANGER
Danger of death
Fatal injuries can result from a crane or lift truck tipover,
or a falling load.
• Make sure the crane, truck and the lifting gear have
sufficient capacity.
Information on the capacity required can be found
on the truck data plate under “Truck Weight Less
Battery” and “Battery Weight”.
Lifting the truck with a crane

GPC860
1. Fully raise the forks.
1. Fully lower the forks.
2. Attach chains and hooks to the cutouts in the floor-
board in front of the battery compartment.
3. Push a thin board on either side between the truck
and the chain.
4. Sling the lifting belts around the forks (see Fig.
GPC840Fig. GPC860 or GPC861).
GPC3000
15
Lifting and Jacking
Towing the truck
DANGER
Danger of death
A truck tipover can result in fatal injuries.
• Make sure the truck has sufficient capacity.
NOTE
In order to be towed, the motor compartment side of
the truck must be raised so that the drive wheel does
not contact the ground. Otherwise the drive wheel
GPC861 would be damaged since the truck brakes are applied
when the truck is switched off.
Lifting the truck with a forklift truck
Towing the truck
1. Fully lower the forks (if possible).
2. Position the forks of the truck that is doing the lifting
under the chassis of the lift truck (see 2. Position the forks of the towing truck under the
Fig. GPC841). truck.
3. Raise the motor compartment side of the truck
approx. 20 mm.
4. Pull the truck slowly and only in a forward direc-
tion (as indicated by the arrow in GPC842).
4 3 4
GPC841
3. Attach the truck securely onto the forks of the truck

doing the lifting (e. g. with a tensioning belt).
2 1 2
GPC842
GPC3000
16
Lifting and Jacking
Jacking up the truck
DANGER
Danger of death
You can be fatally injured by a truck tipover.
• Make sure the jack has sufficient capacity.
DANGER 4 3 4
Danger of death
Fatal accidents can result from improper handling of
the truck or the equipment.
• Never place your hands or other parts of your body
under the truck before it has been supported.
• Always support a raised truck with wooden blocks 2 1 2
or other suitable equipment to relieve the jack.
GPC834
Jacking up the truck
2. Place the jack in the centre of the left hand side of
the skirt (castor wheel) and raise the truck a
maximum of 20 mm (1, Fig. GPC834).
3. Place hard wooden blocks under the front and rear
left of the chassis and lower the truck onto them
(2).
4. Raise the right side in the same way as the left side
(3).
5. Place hard wooden blocks underneath and lower
the truck (4).
GPC3000
17
Taking the Truck out of Service
Taking the Truck out of Service 5. Disconnect the battery.
If the truck is to be out of service for more than

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

NOTE
The hydraulic system must be operated every
3 months to ensure its functionality over the period of
storage.
Test
2. Check the hydraulic oil level.
3. Check the gear unit for leaks.
4. Check the anti-corrosion agent.
GPC3000
18
Recommended Lubricants and Accessories
Recommended Lubricants and An anti-corrosion fluid (Crown no. 805236-004) must

be applied to all screws, washers, nuts, pins, retaining
Accessories rings etc. Carefully protect all electrical connections
and components against corrosion. For detailed infor-
The tables show typical lubricants used by Crown itself
mation, refer to chapter Electrical System.
in its facilities. However, you can use any lubricants
provided they meet the same technical criteria. Service intervals (see page 21) must be adapted to the
conditions of use.
Cold Store Trucks
Special hydraulic oil, lubrication oil and grease must be
used for cold store trucks operating in low temperature
conditions (see table).
Type Lubricant Type Product Manufacturer Crown

Part Number
Transmission oil Hyp 85W90 Aral

GX-D 85W90 Esso
A 053002-004
Mobilube HD85W90 Mobil
Spirax MB90 Shell
Low temperature transmis- Mobil SHC 624 Mobil
AA 053002-009
sion oil
Grease (Multi-Purpose) Aralube HLP2 Aral
LM Grease Castrol
Regulus A2 Century
Beacon EP2 Esso
B 053002-001
EP2 Maxol
Mobiluxe EP2 Mobil
Retinax LX Shell
ALGWMI SKF
Low temperature grease Aralube SKL2 Aral
BB 053002-005
Unirex Lotemp EP Mobil
Hydraulic Oil Vitam GF 32 Aral
Hyspin AWS-32 Castrol
Nuto H32 Esso
DTE 24 Mobil
D 053001-003
Tellus 32 Shell
Hydran LZ 32 Finol
B110 Fuchs Mineralöl-
werke GmbH
DD Hydraulic Oil (Low Temp) Deutz Oel HVI 32 Klockner 053001-009
GPC3000
19
Recommended Lubricants and Accessories
Type Lubricant Type Product Manufacturer Crown

Part Number
Lubrication oil Essolube HDX+40 Esso

G Kowal M 40 Aral 053002-007
Delvac 1240 Mobil
Low temperature lubrication Mobil SHC 626 Mobil
GG 053002-008
oil
M Special grease Molycote® BR-2 Plus Dow Corning -----------------
Lubricants Product Application Crown Part No.
Anti-corrosive agent Tectyl Corrosion inhibitor for cold store 805236-004

trucks
Rubber & Vinyl Dress- Commercial Rubber Components, Plastic Pan- -------------
ing els
GPC3000
20
Routine Maintenance
Routine Maintenance Routinely check for wear, corrosion, damage, and test
component operation and safety when carrying out
The following inspection and maintenance schedule maintenance work. If in doubt, replace components.
assumes single-shift operation under normal condi-
Routine maintenance must be performed either after a
tions.
certain number of service hours or a certain period of
The maintenance intervals must however always be time (whichever is reached first).
adapted to the prevailing operating conditions. In dusty M Months
or otherwise extreme operating conditions including
h Service hours
cold store application, the maintenance intervals spec-
ified must be reduced. Exact details should be dis- X Perform on standard trucks
cussed with a Crown service engineer. C Perform on cold store trucks
X/C Perform on standard and cold store trucks
12 M 24 M 36 M
Position Component Lubri- Action 500 h 1000 h 5000 h

cant
I-1 Truck, general Clean truck if necessary.
NOTE
Note the following when cleaning the
truck:
• Do not use pressure jets and/or sol-
vents on the truck.
X/C
• Do not use metal brushes.
• Do not wet-clean the electrical sys-
tem.
• Do not use flammable cleaning
agents.
• Note the environmental safety guide-
lines.
I-2 Labels, Decalsa Check that labels and decals are legible.
Replace any illegible or severely dam- X/C x
aged decals.
I-3 Steps* Check steps are secure. Test operation
X/C x
and check for damage.
I-4 Load Backrest* Ensure they are securely fitted and check
Grab Handles* for damage.
X/C
Backrest Grab Bar*
Work Assist ™*
I-5 Emergency Discon- Test Emergency Disconnect power
X/C
nectb switch.
I-6 Steeringc Check operation. X/C

I-7 Travel Functionsd Travel in both directions. X/C
GPC3000
21
Routine Maintenance
12 M 24 M 36 M

cant
I-8 Step Sensors* Fold the step down and press the travel
switch. The truck should not travel when X/C
the step is folded down.
I-9 Brake e Test by changing direction with the travel
X/C
switch. Check brake switch.
I-10 Pick Position Con- Test in both directions.
X/C
trol™ f
I-11 Fork Liftg Raise and lower forks. The hydraulics
should cut out on reaching the limit posi- X/C
tions.
I-12 Platform Lift*h Lift and lower the platform.
The hydraulics should cut out on reach-
ing the limit positions.
X/C
The truck should only travel provided the
platform is not raised more than 250 mm
above the ground.
I-13 Load Wheels and Check bearing play.
X/C
Castors Check tyres for wear.
I-14 Drive Wheel Check wheel nut torque (130 Nm).
NOTE
On new trucks or after removing/assem- X/C
bling the drive wheel, torque the wheel
nuts after 100 h to 130 Nm.
Check tyres for wear.
I-15 Hydraulic Lines and Inspect for damage. Check connections
X/C
Hoses for leaks.
I-16 Hydraulic Oil Reser- D/DD Check the hydraulic oil level. Replenish if
X/C
voir necessary.
L-17 Hydraulic Oil D/DD Replace hydraulic oil
NOTE X/C
On new trucks change the hydraulic oil
after the first 500 h or 12 months.
I-18 Hydraulic Filter Replace hydraulic filter. X/C
I-19 Relief Valve (RV) Check the relief valve setting. X/C
I-20 Hydraulic Unit Ensure it is fitted securely. X/C
I-21 Hydraulic cylinder Check the piston rod for damage.
GPC3000
22
Routine Maintenance
12 M 24 M 36 M

cant
I-22 Pump Motor Check carbon brushes, springs and com-

X/C
mutator.
Check pump motor / hydraulic pump cou-
X/C
pling for wear.
Torque pump motor mounting screws. X/C
Torque power cable connections to X/C
I-23 Traction Motor Torque traction motor mounting screws to
X/C
16 Nm.
Torque power cable connections to X/C
I-24 Drive Transmission Torque drive transmission unit mounting
X/C
Unit screws to 70 - 75 Nm.
I-25 Battery Connector Check connector housing, contact
X/C
springs and cables. Clean contacts.
I-26 Electrical System Check insulation of all accessible wires
for damage. Make sure switches and
X/C
connections are fitted securely and check
for damage.
L-27 Battery Cover B/BB Lubricate hinges and lock. X/C
I-28 Main Contactor Clean main contactor contacts and check
X/C
for wear.
I-29 Traction Controller Torque mounting screws to X/C
Check and analyse error log. X/C
I-30 Electromechanical Check the dust shield ring for damage.
Brake Apply weak pressurized air to the abra-
X/C
sion.
Measure the air gap (see page 145).
I-31 Steering Test the steering auto-reset. X/C
I-32 Fork Carriagei Check for cracks (see page 169). X/C
I-33 Fork Carriage Rollersj Check for excessive free play. X/C
I-34 Forks / Fork Tines Check for wear and damage (see
X/C
page 169).
L-35 Mastk Clean the contact surfaces. X/C
B/BB Lubricate contact surfaces. X/C
I-36 Mast End Dampersl Check condition and attachment. X/C
GPC3000
23
Routine Maintenance
12 M 24 M 36 M

cant
I-37 Chain Pulley Yokem Check chain pulley yoke attachment.

Check guide pulleys (see page 164) for X/C
wear, damage and slack.
L-38 Chain Pulleysn Lubricate chain pulleys. X/C
I-39 Lift Chains Clean lift chains and carry out a complete
X/C
inspection (see page 161)
G/GG Lubricate lift chains. X/C
I-40 Chain Anchorso Check chain anchors for damage, corro-
X/C
sion and cracks (see page 164).
I-41 Forksp Check for wear and damage (see
X/C
page 169).
I-42 Lift Mechanismq Lubricate front and rear reversing levers.
Check fork height setting.
X/C
Check that counterfix nuts on adjusting
mechanism and on tie rod are secure.
L-43 Steering Transmission Z/ZZ Clean and lubricate the exposed toothing
X/C
on the steering transmission.
I-44 Drive Transmission K/KK Check oil level. Replenish if necessary
X/C
Unit (see page 49).
Replace the oil (see page 49). X/C
Traction and Steering Carry out a PMT test. An-
Controllers nu-
ally
Entire Truck Carry out the UVV inspection (Germany
An-
only). In other countries: the truck must
nu-
be inspected at intervals determined by
ally
national legislation or regulations.
a. For positions and ordering information refer to the spare parts catalog.
b. See operator manual.
c. See operator manual.
d. See operator manual.
e. See operator manual.
f. See operator manual.
g. See operator manual.
h. See operator manual. Platform Lift option only.
i. On GPC 3045 and GPC 3055.
j. On GPC 3045 and GPC 3055.
k. On GPC 3045 and GPC 3055.
l. On GPC 3045 and GPC 3055.
m. On GPC 3045 and GPC 3055.
n. On GPC 3045 and GPC 3055.
o. On GPC 3045 and GPC 3055.
p. On GPC 3020/40/60.
q. On GPC 3020/40/60.
GPC3000
24
GPC 3020/40/60 Inspection and Lubrication Points
GPC 3020/40/60 Inspection and

Lubrication Points
I-41
I-31
I-30
I-22
L-27
I-29
I-25
I-19
I-23
I-24 I-28
I-15
L-43 I-16 I-20
L-17
I-18
GPC420
GPC3000
25
GPC 3020/40/60 Inspection and Lubrication Points
I-13
I-42
I-44 I-42
I-42
I-14 I-42
I-13
I-13
I-15
GPC421
I-42
I-42
I-12
I-42
GPC422
GPC3000
26
GPC 3045 Inspection and Lubrication Points
GPC 3045 Inspection and Lubri-

cation Points
I-27
I-31
I-3 I-30
I-22
I-25
I-29
I-30
I-19
I-24
I-28
I-23 I-15
L-43 I-16 I-20
L-17
I-18
GPC424
GPC3000
27
I-13
I-44
I-14
I-13
I-15
GPC425
I-36
I-33
I-32
I-37, L-38
L-35
I-39, I-40
GPC426
GPC3000
28
GPC 3055 Inspection and Lubri-

cation Points
L-27
I-22
I-31
I-29
I-3
I-19
I-25
I-30
I-24
I-23
L-43 I-16
L-17 I-28
I-18 I-20 I-15
GPC428
GPC3000
29
I-36
I-33
I-32 I-34
L-35
I-39 L-38
I-21 I-37
I-40
GPC427
I-13
I-44
I-13
I-14 I-15
GPC429
GPC3000
30
Torques
Torques
Standard Torques
NOTE
The torques listed in the manual always take prece-
dence over standard torques.
Standard Screws and Nuts
Grade: 8 and 8.87 10 and 10.9 12 and 12.9

Thread Size 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
Umbrako screws and nuts
Grade 10 and 10.9 12 and 12.9

Thread Size 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
GPC3000
31
Notes:
32
HYDRAULIC SYSTEM
33
Notes:
34
HYDRAULIC SYSTEM
General
General Oil Change

The oil reservoir does not have a drain plug. The oil
must either be suctioned off, or the hydraulic unit re-
WARNING
moved (see page 38) and the oil poured out via the
High pressure hydraulic system! filler neck.
Risk of injury from escaping hydraulic oil.
To avoid accidents: Capacity
• Depressurise the hydraulic system before opening
any sections of it.
• Tighten all connections before pressurising the WARNING
system. Health risk. Observe the manufacturer’s safety in-
• Keep hands and body away from pressurized fluid. structions when handling solvents and lubricants.
• Only trace leaks with a piece of paper or card-
board. NOTE
Whenever a high pressure fluid enters the skin it must The maximum reservoir capacity on the GPC 3020/40
be treated as a medical emergency. is approx. 0.7 litres, on all other models approx.
Seek medical assistance even if the skin appears nor- 1.9 litres.
mal at first.
1. When the lift (and platform if applicable) is fully low-
ered, add an approved hydraulic oil up to the bot-
Hydraulic Lines and Ports tom mark of the filler neck.
• Apply pressurised air to all hoses and lines before NOTE

assembling them, to remove any loose particles.
The oil level should not deviate by more than +/- 5 mm
• Once a steel or plastic line has been bent, it is per- from this level.
manently damaged. These must be replaced even
if the damage is not externally visible.
• Any hose which bends during operation in its nor-

mal assembly position must also be replaced.
• All hoses and lines must have sufficient clearance

from other surfaces or edges that could result in
wear or cuts or where the hoses or lines could get
caught.
• All connections must be tight and without leaks.
Bleeding the hydraulic system

Whenever work has been performed on hydraulic com-
ponents, the hydraulic system must be flushed and
bled (see page 44).
Drift Test
When all the work has been carried out on the hydrau-
lic components, a drift test must be performed (see
page 44).
GPC3000
35
HYDRAULIC SYSTEM
Relief Valves
Relief Valves 2.2 kW unit, hydraulic manifold with two functions

(see Fig. GPC469):
Relief Valve RV1 protects the lifting mechanism against
overload. RV2 restricts the hydraulic pressure for plat-
form lift. RV1
1.2 kW unit, hydraulic manifold with one function RV2
(see Fig. GPC474):
RV1 A
B
A
GPC474
2.2 kW unit, hydraulic manifold with one function

(see Fig. GPC470): GPC469
RV1
GPC470
GPC3000
36
HYDRAULIC SYSTEM
Relief Valves
Replacing relief valves RV21 test

1. With the truck at operating temperature place a
165 kg test load on the centre of the platform. The
WARNING
load should lift easily.
Risk of serious injury! 2. Now place a 180 kg weight on the centre of the
Avoid accidents by: platform. It should not be possible to raise this load.
• Switching the truck off (Relief valve opens).
• Disconnecting the battery.

Adjusting RV1/RV2
• Preventing the truck from being switched on again.
1. Open the locking mechanism.
• Jacking up the truck and preventing it from rolling
away (see page 15). 2. Hold the adjusting screw and loosen the counter-
nut.
1. Depressurise the hydraulic system.
– Turn the adjusting screw clockwise to increase
2. Remove the locking mechanism. the limit at which the valve opens.
3. Unscrew the relief valve (1). – Turn the adjusting screw anti-clockwise to de-
4. Remove the O ring and the strainer from the valve crease the limit at which the valve opens.
seat if they are still in there. 3. Counterfix the adjusting screw again and attach
5. Apply a thin coat of hydraulic oil to the new O ring the locking mechanism.
and position it with the strainer in the valve seat.
6. Apply a thin coat of hydraulic oil to the relief valve
(1). Screw it into the valve seat and tighten.
7. Refit the hydraulic unit and adjust the relief valve.
Testing and adjusting the relief

valves
WARNING
Do not operate the pump unit unless it is fixed to
the chassis.
The high torque will twist the unit if it not bolted on. This
can result in short circuits and damage.
RV1 test
NOTE
The rated capacity can be found on the truck's data
plate.
1. With the truck at operating temperature place a
test load of 110 % of the rated capacity on the
forks. The load should lift easily.
2. Now lift a test load 110 % of the rated capacity
+100 kg. It should not be possible to raise this
load. (Relief valve opens).
1. Only on trucks with platform lift:
GPC3000
37
HYDRAULIC SYSTEM
Hydraulic Unit
Hydraulic Unit 1. Torque the attachment screws of the unit onto the
chassis with 40 +4/-0 Nm.
2. Now bleed the hydraulic system (see page 44). If
WARNING the pump has been replaced, then proceed initially
as described in the Start Up Procedure section
Risk of serious injury! (see page 15).
Avoid accidents by:
• Switching the truck off 1.2 kW hydraulic unit disassembly
The hydraulic unit must be dismantled in order to re-
place the following components:
away (see page 15). • Hydraulic pump
• Suction filter
WARNING
• Return line filter
High pressure hydraulic system!
Risk of injury from escaping hydraulic oil. • Hydraulic reservoir
To avoid accidents:
• Depressurise the hydraulic system before opening Dismantling
any sections of it. See Fig. GPC601, page 40)
• Tighten all connections before pressurising the
system.
• Keep hands and body away from pressurized fluid. WARNING
• Only trace leaks with a piece of paper or card- Health risk. Observe the manufacturer’s safety in-
board. structions when handling solvents and lubricants.
Whenever a high pressure fluid enters the skin it must 1. Remove the hydraulic unit.
be treated as a medical emergency.
Seek medical assistance even if the skin appears nor- 2. Drain the oil via the filler neck and dispose of it in
mal at first. accordance with environmental regulations.
3. Remove the tie rod (1).
Hydraulic unit removal 4. Lift the motor out from the top. Make sure the motor
does not fall apart.
1. Depressurise the hydraulic system.
5. Remove the four screws (27) and washers (26)
2. Prevent the truck from rolling away and being
from the flange (25) of the reservoir (22).
switched on again.
6. Remove the reservoir and flange.
3. Remove all electrical connections from the pump
motor. The pump can now be removed.
4. Disconnect hydraulic lines from manifold. 7. Loosen the four screws (M6 x 50, hex. socket) from
the motor side of the hydraulic manifold and lift off
5. Seal any open ports immediately with dummy
the pump and seal (10).
plugs.
8. Remove and dispose of the old seals and filter
6. Unscrew the hydraulic unit from the chassis and
(21).
place it on a clean workbench.
9. Clean all components (except for the motor) with
clean de-greasing solution.
Hydraulic unit assembly
Assembly is the reverse of disassembly.
GPC3000
38
HYDRAULIC SYSTEM
Hydraulic Unit
Assembly 8. Now add hydraulic oil up to the bottom mark of the

filler neck. For the hydraulic oil grade see Recom-
1. Fit a new filter (21) to the pump. mended Lubricants and Accessories chart on page
2. Apply a thin layer of oil to the seal (10) and insert it. 19.
3. Fit the pump (note the alignment. See Fig.

GPC601, page 40) and tighten with four M6 x 50
screws. Torque crosswise to 18 ±2 5 Nm.
4. Fit the reservoir with a new, slightly lubricated seal
(23).
5. Attach the flange (25).
6. Fit the screws (27) and washers (26). Torque the
screws to 8 ± 1.2 Nm.
The next stage is to position the pump motor. Make
sure that the connections are properly aligned.
7. Place the motor on the hydraulic manifold in such
a way that the drive shaft carrier slides into the
pump shaft recess. Align the motor and attach it
with the tie rods (1). Torque to 8 ± 1.2 Nm.
8. Reassemble the hydraulic unit (see page 38).
Start Up Procedure
To check for leaks, all components must be completely
clean and dry prior to starting up.
NOTE
Never allow the pump to run dry (without oil).
1. Make sure the hydraulic unit is fitted correctly. In
particular, the pressure ports must be tight.
2. Add hydraulic oil initially up to half the reservoir
height via a filter with a minimum 10 µm retention
rate. For the hydraulic oil grade see Recom-
mended Lubricants and Accessories chart on page
19.
3. Activate lifting for approx. 30 seconds to bleed the
system. The oil in the reservoir will foam.
4. Check the pressure port and surrounding hydraulic
components for leaks.
5. Switch off the truck and leave it to stand for approx-
imately 20 minutes. During this time the air will sep-
arate from the oil in the container.
6. When there is no more foam in the container, add
oil again up to half the maximum level and bleed
the system again until no more foam appears.
7. Fully lower the forks - and the platform if applica-
ble.
GPC3000
39
HYDRAULIC SYSTEM
Hydraulic Unit
GPC601
GPC3000
40
HYDRAULIC SYSTEM
Hydraulic Unit
2.2 kW hydraulic unit disassembly 10. Remove the filter, flow controller, restrictor throttles
and all used valves and distributor blocks (see
The hydraulic unit must be dismantled in order to re- Figs. GPC602 and GPC064 respectively).
place the following components:
11. Fit the filter, flow controller, restrictor throttles and
• Hydraulic pump all used valves and distributor blocks (see Figs.
GPC602 and GPC064 respectively) with new seals
• Suction filter into the new hydraulic pump (3).
• Flow controller 12. Attach the motor again in the correct position.
13. Assemble the hydraulic unit in the truck (see Hy-
• Hydraulic reservoir draulic unit assembly, page 38).
Dismantling
See Fig. GPC602, page 42) For trucks with platform
lift see Fig. GPC064, page 43.
WARNING
Health risk. Observe the manufacturer’s safety in-
structions when handling solvents and lubricants.
1. Remove the hydraulic unit (see page 38).
2. Drain the oil via the filler neck and dispose of it in
accordance with environmental regulations.
3. Remove the tie rods.
4. Lift the motor out from the top. Make sure the motor
does not fall apart. Take the coupling (2) out of the
hydraulic manifold if it is still there.
5. Remove the four screws (7) from the reservoir
flange.
6. Remove the reservoir and flange.
Replacing the filter
7. Loosen the clamp and replace the filter (16) with a
new one.
Replacing the flow controller
8. Loosen the clamp on the flow controller and pull off
the hose.
9. Unscrew the flow controller (9) from the distributor
block and replace it with a new flow controller.
Replacing the pump1
NOTE
Do not re-use old seals and filters.
1. The pump is contained within the valve block

and is only available as a complete unit.
GPC3000
41
HYDRAULIC SYSTEM
Hydraulic Unit
18
GPC602
GPC3000
42
HYDRAULIC SYSTEM
Hydraulic Unit
18
GPC064
GPC3000
43
HYDRAULIC SYSTEM
Bleeding and Flushing the System
Bleeding and Flushing the Sys- 4. Tighten the bleed screw securely.
tem 5. Clean any contaminated areas with hydraulic fluid.
Flushing
WARNING
High pressure hydraulic system!
• Fully raise the fork carriage.
Risk of injury from escaping hydraulic oil.
To avoid accidents:
DANGER
any sections of it. Risk of fatal injury!
• Tighten all connections before pressurising the Never stand underneath a raised and unsecured fork
carriage.
system.
The fork carriage can automatically lower and result in
• Keep hands and body away from pressurized fluid. fatal injuries.
• Only trace leaks with a piece of paper or card- Use suitable hard wooden blocks to prevent the raised
board. fork carriage from lowering.
Whenever a high pressure fluid enters the skin it must
be treated as a medical emergency.
• When the fork carriage is raised visually inspect for
Seek medical assistance even if the skin appears nor- leaks.
mal at first. • Lower the fork carriage while checking the opera-
Hydraulic circuits need to be flushed after repair of hy- tion.
draulic components and bled of all air.
• Raise and lower carriage rapidly for a minimum of
10 cycles to flush the system.
Before flushing and bleeding the system
1. Check all hydraulic ports for leaks.
Drift Test
2. Make sure that all filters - where applicable - are
fitted.
3. With the forks and platform lowered, add hydraulic DANGER
fluid up to the maximum level in the reservoir.
Risk of fatal injury!
Never stand or work under a suspended load.
Bleeding A crashing load can cause fatal injuries to you or other
people.
• All drift tests should be conducted with a capacity

DANGER
load (refer to capacity plate for the rated capacity
Risk of fatal injury! of your truck).
Never stand underneath a raised and unsecured fork
carriage.
• The material used for the test load must be evenly
The fork carriage can automatically lower and result in distributed within a 1.2 m x 0.8 m pallet and must
fatal injuries. be attached to the fork carriage.
Use suitable hard wooden blocks to prevent the raised 1. Fully raise the fork carriage with maximum rated
fork carriage from lowering. load.
1. Slowly extend the lift cylinder until just before the – The load must not drift down more than 50 mm
maximum lift height. within 5 minutes.
2. Slowly open the fork carriage bleed screw and col- Occasionally internal leaks in the cylinder may cause
lect the fluid. the fork assembly to lower slowly. However, this may
3. Activate lifting until the a constant stream of hy- also be due to leaks in the check valves, pilot valves
draulic fluid emerges from the bleed screw. etc.
GPC3000
44
HYDRAULIC SYSTEM
Bleeding and Flushing the System
1. Flush the hydraulic system (see page 44).

2. Now repeat the drift test.
GPC3000
45
Notes:
46
DRIVE UNIT
47
Notes:
48
DRIVE UNIT
Changing the Transmission Oil
Changing the Transmission Oil 2. Power up the truck and apply the steering to turn
the drive wheel so that the refill plug (1) and the
drain plug (2) on the gear unit are accessible.
WARNUNG 3. Switch the truck off and prevent it from being
switched on again.
Health risk
Observe the manufacturer’s safety instructions when 4. Place a flat tray with a minimum capacity of 2 litres
handling solvents and lubricants. underneath to collect the used oil.
The oil should have reached operating temperature
before changing. This will ensure that it flows away
quickly and any contamination is kept in suspension.
Oil change intervals: see “Routine Maintenance”, page
21. For authorised oil grades see Recommended
Lubricants and Accessories, page 49. Approximate
capacity 1.8 litres.
INFORMATION
The refill plug can only be accessed if the truck is
raised. Therefore a crane or another truck with
sufficient capacity must be used to raise the truck.
Jacking up the truck is prohibited for safety reasons. 1
If the truck can only be raised by a certain amount, the

drive motor can be removed (siehe Seite 132) in order
to add oil via the open gear unit cover.
GEFAHR
Danger of death
You can be killed by a falling truck.
Use only lifting gear, slings and blocks with
Before working underneath a raised truck:
• Support the truck raised with a crane in such a way
that it cannot fall down even if the lifting gear
cracks or the crane fails.
• If the truck is raised with a forklift truck, it must be 2
secured on the forks of the truck doing the lifting, to
prevent it from slipping and falling off. The lift GPC411
mechanism of the truck doing the lifting must be For gear units with a refill plug (1, Fig. GPC411):
physically chocked before you can work under the
raised load. – Unscrew the refill plug.
1. Raise the truck with a crane or forklift truck only as For gear units without a refill plug:
far as is absolutely necessary (see “Lifting the – Remove the drive motor (siehe Seite 132).
Truck” on page 15, or “Lifting the truck with a forklift
truck” on page 16). The drive wheel must however 5. Unscrew the oil drain plug (2) and collect the oil.
be clear of the ground. Secure it against accidental 6. Dispose of used oil in accordance with
lowering. environmental and local regulations.
GPC3000
49
DRIVE UNIT
Changing the Transmission Oil
Now add new oil:

7. Clean the drain plug (2), screw it on and tighten.
INFORMATION
Make sure to use the correct oil grade: cold store trucks
require a different type of oil than standard trucks.
8. Add a suitable gear oil (see Recommended
Lubricants and Accessories, page 49).
– Capacity: approx. 1.8 litres
9. Clean the refill plug (1), screw it on and tighten.
10. Remove the jack from the truck and the device to
prevent it from being switched on.
11. Test the steering.
12. Lubricate steering toothing with Type M lubricant
(see Recommended Lubricants and Accessories,
page 49) .
GPC3000
50
DRIVE UNIT
Components
Components
The drive unit consists of several components. A 1
steering assembly with a steering gearbox and servo 2
motor is incorporated via an intermediate flange.
The drive unit components include the following:
• Brake (1)
• Steering assembly (3) 6
• Drive transmission unit (4) 3
• Drive wheel (5)
• Drive motor (6)

If the drive unit is to remain in the truck, the 5
following components can be removed and
installed again:
• Brake (siehe Seite 145)

4
• Drive motor (siehe Seite 132)
• Steering assembly (siehe Seite 134)
• Drive wheel (siehe Seite 55)
• Shaft seal of the driven shaft on which the drive

wheel is seated (siehe Seite 52).
GPC418
INFORMATION
In the following sections we will first describe
operations that can be performed on the drive
transmission unit with the drive unit installed. This will
be followed by the removal and complete disassembly
of the drive transmission unit.
GPC3000
51
DRIVE UNIT
Replacing the shaft seal of the driven shaft
Replacing the shaft seal of the

driven shaft
84
83 52 1
85 18 2
53
82 19
81 3
80 54 20 4
57
79 55 21
5
22
78 56
6
77 23
24
76
75 7
58
87 25
59
74 26
73 27
28 8
60 9
61 10
12 13
72 64 62 11
63 29
30
88 14
31
32 15
71
16
33
70
17
69 34 35
86 36
37 38 39
68 40 41
67
66
45
44
46
65 42
47
43
48
49 51
50
GPC412
GPC3000
52
DRIVE UNIT
Special Tools Required 2. Place the shaft seal (51) onto the driven shaft (50).
3. Press on a new bearing (34).
Tool to press in the shaft seal (part no. 822671).
4. Fit the shims (35) and bushing (36).
Preparation 5. Push the pre-assembled driven shaft into the gear
unit.
1. Jack-up and secure the truck page 49).
6. Assemble the washer (40) and screw (41).
2. Drain the oil (siehe Seite 49).
7. Torque the screw (41) to 260 Nm.
3. Remove the drive wheel (siehe Seite 55).
Now check the friction torque of the driven shaft:
Shaft Seal Removal – It should be 4 - 10 Nm

Adjust if beyond the tolerance range.
The driven shaft must be removed in order to replace
the shaft seal. Adjusting the driven shaft friction torque
All reference numbers in the following section refer Remove the driven shaft again (see Removing the
to Figure GPC412 on page 52. driven shaft, steps 4 to 6).
Removing the driven shaft • To reduce the friction torque:
For gear units with a screw-on cover (43): – Increase the rated size of the shims (35).
– Remove the screws (42) and take off the cover • To increase the friction torque:
(43).
– Reduce the rated size of the shims (35).
For gear units with a press-on cover (43):
Refit the driven shaft (see Driven shaft assembly).
INFORMATION Check the friction torque again. Repeat the adjustment
if it is still out of range.
Press-on covers become inevitably damaged when
removed. The driven shaft friction moment is within the
tolerance range:
– Strike through the cover with a large
screwdriver and a hammer. 8. Using the special tool press the shaft seal (51)
(part no. 822671) over the holes in the flange on
– Lever off the cover with the screwdriver. the driven shaft into its correct position.
4. Loosen the screw (41) and remove it together with For gear units with a screw-on cover (44):
the washer (40).
– Clean the contact surfaces of the housing (44)
5. Press off the driven shaft (50). and cover (43) with a suitable solvent.
6. Remove the shims (35) and bushing (36). – Apply a sealing compound to the contact
7. Remove the bearing (34) and dispose of it. surfaces in accordance with the manufacturer’s
instructions. We recommend either Loctite®
8. Remove the shaft seal (51) from the driven shaft.
Dispose of the shaft seal. 518, Loctite® 574 or Terostat® MS935.
– Attach the cover (43) with the screws (42).
Driven shaft assembly Torque the screws (43) to 10 Nm.
INFORMATION
WARNUNG
Before adding oil, check the hardening times required
Health risk. Observe the manufacturer’s safety for the sealing compound used.
instructions when handling solvents and lubricants.
1. Grease the sealing lip of a new shaft seal.
GPC3000
53
DRIVE UNIT

– Fit a new cover (43) with the sealed side facing
out.
VORSICHT
Never strike the cover without a washer supporting it
underneath. Otherwise you will damage the cover.
– Using a plastic hammer and a secure washer
(∅ 148 - 150 mm) underneath, strike the cover
evenly without damaging it.
– Insert and tighten the drain plug (45).
9. Add oil (see Changing the Transmission Oil, page
49)
GPC3000
54
DRIVE UNIT
Drive Wheel and Wheel Bolts
Drive Wheel and Wheel Bolts 2. Power up the truck and apply the steering to turn
the drive wheel so that the wheel nuts can be
accessed through the hole (1, Fig. GPC419).
Drive Wheel Disassembly 3. Switch off the truck, disconnect the battery and
prevent it from being switched on again.
GEFAHR 4. Unscrew the wheel nuts.

5. Remove the drive wheel.
Danger of death
Use only lifting gear, slings and blocks with Drive Wheel Assembly
Before working underneath a raised truck: Assembly is the reverse of disassembly. Torque the
• Support the truck raised with a crane in such a way wheel nuts crosswise to 130 Nm.
cracks or the crane fails. Replacing the Wheel Bolts
• If the truck is raised with a forklift truck, it must be
secured on the forks of the truck doing the lifting, to 1. Disassemble the drive wheel (see Drive Wheel
prevent it from slipping and falling off. The lift Disassembly).
mechanism of the truck doing the lifting must be 2. Remove any damaged wheel bolts with a bolt
physically chocked before you can work under the extractor.
raised load.
3. Fit new wheel bolts (49, Fig. GPC412, page 52)
with Loctite® 243™.
4. Re-assemble the drive wheel.
GPC419
1. Raise the truck with a crane or forklift truck only as

far as is absolutely necessary (see “Lifting the
Truck” on page 15, or “Lifting the truck with a forklift
truck” on page 16). The drive wheel must however
be clear of the ground. Secure it against accidental
lowering.
GPC3000
55
DRIVE UNIT
Replacing the Drive Unit
Replacing the Drive Unit

The truck must be raised relatively high in order to
remove the entire drive unit.
1
GEFAHR
1
Danger of death
Use only lifting gear, slings and blocks with
Before working underneath a raised truck:
• Support the truck raised with a crane in such a way
cracks or the crane fails.
• If the truck is raised with a forklift truck, it must be
secured on the forks of the truck doing the lifting, to
prevent it from slipping and falling off. The lift
mechanism of the truck doing the lifting must be 1
physically chocked before you can work under the
raised load.
Special Tools Required

• A home-made device for holding the drive unit.
Removal
1. Disconnect the battery and prevent the truck from
being switched on again.
2. Remove the battery if necessary (take into account
GPC414
the capacity of the equipment used to raise the
truck).
Assembly
3. Disconnect all electrical connections to the drive
motor, brakes, steer sensor and steer motor. 1. If a new gear unit is to be installed, remove the
steer sensor from the old gear unit and attach it to
4. Raise the truck either with another forklift truck or
the new one (see Steering).
with a crane (siehe Seite 15) so that the device for
holding the drive unit can be pushed underneath 2. Assemble the drive unit in the reverse order of
the truck. disassembly.
5. Drain the oil (siehe Seite 49). 3. Torque the mounting screws (1, Fig. GPC414) to
70 - 75 Nm.
6. Push the device for holding the drive unit
underneath the truck. 4. Add oil (siehe Seite 49).
7. Remove the mounting screws (1, Fig. GPC414).
8. Raise the truck until the drive unit is free.
9. Pull out the drive unit or move the raised truck.
GPC3000
56
DRIVE UNIT
Drive Transmission Unit
84
83 52 1
85 18 2
53
82 19
81 3
80 54 20 4
57
79 55 21
5
22
78 56
6
77 23
24
76
75 7
58
87 25
59
74 26
73 27
28 8
60 9
61 10
12 13
72 64 62 11
63 29
30
88 14
31
32 15
71
16
33
70
17
69 34 35
86 36
37 38 39
68 40 41
67
66
45
44
46
65 42
47
43
48
49 51
50
GPC412
GPC3000
57
DRIVE UNIT
Repairing the Drive Transmission Driven shaft removal

Unit For gear units with a screw-on cover (43):
10. Remove the screws (42) and take off the cover
(43).
VORSICHT
Transmission repair requires special expertise,
experience and tools such as presses, extractors, INFORMATION
measuring equipment and assembly aids.
If you cannot meet these particular requirements, use Press-on covers become inevitably damaged when
a new drive transmission unit. removed.
11. Strike through the cover with a large screwdriver
INFORMATION and a hammer.
Replace all bearings and seals when repairing. 12. Lever off the cover with the screwdriver.
13. Using a mandrel (1, Fig. GPC415) in the hole of the
Preparation pinion (30) prevent the gear unit from turning.
1. Remove the drive unit (siehe Seite 56). 14. Loosen the screw (41) and remove it together with
2. Remove the drive motor (siehe Seite 132). the washer (40).
3. Remove screws (57). 15. Press off the driven shaft (50).
4. Lift off the steering assembly. 16. Remove the shims (35) and bushing (36).
5. Remove screws (58). 17. Remove the bearing (34) and dispose of it.
6. Extract the live ring bearing (59). 18. Remove the shaft seal (51) from the driven shaft.
Dispose of the shaft seal.
7. Remove the bleeder valve (64).
8. Remove the O-ring (60), shim (61), supporting ring Bevel gear and bevel pinion removal
(62) and retaining ring (63).
9. Remove the gear unit cover (88).
Dismantling
See Figure GPC412, page 57.
GPC416
GPC415
19. Remove the bevel gear (39) and bearing (37) and
washer (38) from the housing (44) (siehe
Abb. GPC416).
GPC3000
58
DRIVE UNIT
20. Push the bearing (37) off the bevel gear (39) (this 9. Screw the groove nut (29) onto the bevel pinion
can be done through 2 holes in the bevel gear) and shaft and torque to 35 Nm.
remove the washers (38).
10. Remove the mandrel.
After installing, check the friction torque:
pinion (30) prevent the gear unit from turning.
11. Check the friction torque of the bevel pinion shaft
22. Remove the groove nut (29) (siehe Abb. GPC415).
(0.1 – 0.2 Nm).
23. Pull the bevel pinion shaft (48) and conical roller
Adjust the friction torque if necessary:
bearing (47) and washers (32) out from
underneath the gear unit. 12. Using a mandrel (1, Fig. GPC415, page 58) in the
hole of the pinion (30) prevent the pinion from
24. Remove the washers (32).
turning.
25. Remove the conical roller bearing (47) from the
13. Remove the groove nut, item 15.
bevel pinion shaft (48).
14. Pull the bevel pinion shaft (48) and conical roller
26. Pull or press the pinion (30) and the conical roller
bearing (47), supporting ring and shim (32) out
bearing (31) off the housing (44).
from underneath the gear unit.
27. Pull the conical roller bearing (31) off the pinion
(30). • To reduce the friction torque:
28. Take the outer rings of the conical roller bearings – Add a shim.
(31, 47, 37, and 34) off the housing (44).
• To increase the friction torque:
29. Remove the washer (46) from the housing (44).
– Remove a shim.
Assembly 15. Fit the bevel pinion shaft (48) back into the pinion
(30).
INFORMATION 16. Using a mandrel (1, Fig. GPC415) in the hole of the
pinion (30) prevent the pinion from turning.
Use only new bearings and seals.
17. Screw the groove nut (29) onto the bevel pinion
Bevel pinion and drive pinion shaft and torque to 35 Nm.
1. Insert the washer (46) in the housing (44). 18. Remove the mandrel.
2. Use a press to force the outer rings of the conical 19. Check the friction torque again and keep adjusting
roller bearings (31, 47, 37, and 34) into the housing it until it is within a tolerance of 0.1 - 0.2 Nm.
(44).
3. Press the conical roller bearing (47) onto the bevel
pinion shaft (48).
4. Fit a shim (32) onto a supporting ring (rated size of
two shims combined = 2.2 mm).
5. Press the conical roller bearing (31) onto the pinion
(30).
6. Fit the pinion (30) in the correct position in the
housing (44).
7. Fit the bevel pinion shaft (48) into the pinion (30).
The bevel pinion shaft and the pinion must now be
installed into the gear unit:
pinion (30) prevent the pinion from turning.
GPC3000
59
DRIVE UNIT
Bevel gear
GPC416
20. Place the shim (38) onto the bevel gear (39). The
rated size of the shim is 1.0 mm. GPC417
21. Press the conical roller bearing (37) onto the bevel 24. Check the bevel gear toothing on the reference
gear (39). diameter of the pinon (30) (siehe Abb. GPC417):
22. Install the bevel gear in the correct position in the – Clearance tolerance: 0.2 - 0.5 mm
housing (44). Adjust the clearance if necessary:
23. Assemble and install the driven shaft and adjust 25. Loosen the screw (42) and remove it together with
the friction torque (see Driven shaft assembly, the washer (41).
page 53).
26. Press off the driven shaft (50).
27. Remove the bevel gear (39), conical roller bearing
(37) and washer (38) from the housing (44) .
28. Push the bearing (37) off the bevel gear (39) (this
can be done through 2 holes in the bevel gear).
Remove the washers (38) and adjust the
thickness:
– To reduce the clearance: Increase the number
of shims (38).
– To increase the clearance: Reduce the number
of shims (39).
29. Fit the washers (38) with the adjusted size.
30. Press on the conical roller bearing (37).
31. Fit the pre-assembled bevel gear in the correct
position in the housing.
32. Re-fit the driven shaft and check the clearance
again. Keep adjusting if necessary until the
GPC3000
60
DRIVE UNIT
clearance lies within the tolerance range of 0.2 – 41. Assemble the drive motor (siehe Seite 132).
0.5 mm.
42. Assemble the drive unit (siehe Seite 56).
33. Using the special tool press the shaft seal (51)
(part no. 822671) over the holes in the flange on
the driven shaft into its correct position.
For gear units with a screw-on cover (44):
– Clean the contact surfaces of the housing (44)
and cover (43) with a suitable solvent.
– Apply a sealing compound to the contact
surfaces in accordance with the manufacturer’s
instructions. We recommend either Loctite®
518, Loctite® 574 or Terostat® MS935.
– Attach the cover (43) with the screws (42).
Torque the screws (43) to 10 Nm.
INFORMATION
Before adding oil, check the hardening times required
for the sealing compound used.
– Fit a new cover (43) with the sealed side facing
out.
VORSICHT
Never strike the cover without a washer supporting it
underneath. Otherwise you will damage the cover.
– Using a plastic hammer and a secure washer
(∅ 148 - 150 mm) underneath, strike the cover
evenly without damaging it.
34. Fit the cover (31) in the correct position.
35. Fit the live ring bearing (60) in the correct position
and fasten with the screws (59). Torque to 25 Nm.
36. Install the bleeder valve (61).
37. Insert and tighten the drain plug (42).
38. Remove the O-ring (53), shim (54), supporting ring
(55) and retaining ring (56).
39. Attach the steering gear together with the steer
motor and intermediate flange.
INFORMATION
Before adding oil: Check the hardening times required
for the sealing compound used.
40. Add oil (see Changing the Transmission Oil, page
49).
GPC3000
61
Notes:
62
ELECTRICAL SYSTEM
63
Notes:
64
ELECTRICAL SYSTEM
General
General first two digits indicate the wire colour while the last two
digits are counter numbers.
Third party component wires may pose an exception to
Wire colour code this rule:
The wires used in the truck are colour-coded and num-
bered according to their function. The first digit or the
Abbreviation Colour Colour number Function
BLK Black 0 ** Digital signal

BRN Brown 1 ** Analog signal
RED Red 2 ** Positive not connected
ORG Orange 3 ** +12 VDC - transformer
YEL Yellow 4 ** Third DC - transformer
GRN Green 5 ** Negative not connected
BLU Blue 6 ** Negative, insulated
VIO Violet 7 ** +5 VDC - transformer
GREY Gray 8 ** Fourth DC - transformer
WHT White 9 ** Various
RED/WHT Red/White 29 ** Positive connected
GRN/WHT Green/White 59 ** Negative connected
** Numbers 01 to 99
GPC3000
65
ELECTRICAL SYSTEM
Contact Symbol Abbreviations
Abbrevia- Description Abbreviation Description (Sheet 1 of 2)

tion
Ka Relays LMS Limit switch
ACS Travel switch LOS Lower Switch

AXS Auxiliary function switch ORS Override switch
BRS Brake switch POT Potentiometers
DIS Travel direction switch RA Raise potentiometer
DRS Door switch RAS Raise switch
EDS Emergency power disconnect REA Reach potentiometer
EM Encoder module RS Reverse switch
ENC Encoders SAS Safety reverse switch
FS Forward switch SDS Start switch
HBS Handbrake switch SES Seat switch
HNS Horn switch SSS Sideshifter switch
HSS Rabbit/Turtle toggle switch THS Thermo switch
KYS Key switch TLT Tilt switch
LGS Light switch WAS Walk-along / pedestrian mode switch
BV (AK) Battery voltage after the key switch M2 (PM) Pump motor
BDI Battery discharge indicator MRC Control module
BR Brake OHGD Overhead guard display
BWI Brush wear display P Pump contactor
CA Cable connection PC Plug connection
F Field coil connection 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 block
JC Socket = counterpart to PC TMM Truck management module
LINE Main contactor TT Hourmeter
M1 (TM) Traction motor VMN Motor driver (volt motor negative)
GPCSR Safety switch - RH side restraint GCSL Safety switch - LH side restraint
PLS Platform switch TCM Traction motor
PS Pressure switch HR Heating
HCM Hydraulic control module ALM Travel alarm
GPC3000
66
ELECTRICAL SYSTEM
Abbrevia- Description Abbreviation Description (Sheet 2 of 2)

tion
RECEIVER Receiver TRANSMITTER Transmitter

BDI Combination instrument CHARGER On-board charger
BRK Electromagnetic brake DR Driver
SLS Sideshift left switch SRS Sideshift right switch
ECS Lift control switch --- ---
a.f If one of the above abbreviations is used more than once, a number extension will be used, e.g. SV1, SV2 etc.
GPC3000
67
ELECTRICAL SYSTEM
Electrical Symbols
Electrical Symbols
Europe USA Description Europe USA Description
Wires joining Switch applied manually
Wires crossing Solenoid valve
Wire connection Throttle / coil
Plug / socket Resistor
Wire strap Capacitor
Terminal board Potentiometer
Fuse Varistor
V
Assembly Thermal protector
Contact, normally Lamp

open
Contact, normally Horn

closed
Selective switch Battery
Contactors/relays Diode
Slow release contac- Breakdown diode

tor / relay
Time delay contactor LED

/ relay
Switch, normally Transistor

open
GPC3000
68
ELECTRICAL SYSTEM
Electrical Symbols
Europe USA Description Europe USA Description
Push button, me- MOSFET

chanically actuated
Pushbutton, hydrau- Thyristor

lically actuated
Emergency power Comparator

disconnect
Motor armature
---
GPC3000
69
ELECTRICAL SYSTEM
Components
Components
GPC 3020/40/60 without Platform Lift

(GPC 3040 shown)
GPC430
GPC3000
70
ELECTRICAL SYSTEM
Components
GPC 3020/40/60 without platform lift

(GPC 3040 shown)
GPC431
GPC3000
71
ELECTRICAL SYSTEM
Components
GPC 3020/40/60 without platform lift

(GPC 3040 shown)
GPC432
GPC3000
72
ELECTRICAL SYSTEM
Components
GPC 3040/60 with Platform Lift

(GPC 3040 shown)
GPC433
GPC3000
73
ELECTRICAL SYSTEM
Components
GPC 3040/60 with platform lift

(GPC 3040 shown)
GPC433
GPC3000
74
ELECTRICAL SYSTEM
Components

(GPC 3040 shown)
GPC434
GPC3000
75
ELECTRICAL SYSTEM
Components

(GPC 3040 shown)
GPC435
GPC3000
76
ELECTRICAL SYSTEM
Components
GPC 3045 with Platform Lift
GPC436
GPC3000
77
ELECTRICAL SYSTEM
Components
GPC 3045 with platform lift
GPC437
GPC3000
78
ELECTRICAL SYSTEM
Components
GPC 3045 with platform lift
GPC438
GPC3000
79
ELECTRICAL SYSTEM
Components
GPC 3055
GPC439
GPC3000
80
ELECTRICAL SYSTEM
Components
GPC 3055
GPC440
GPC3000
81
ELECTRICAL SYSTEM
Components
GPC 3055
GPC441
GPC3000
82
ELECTRICAL SYSTEM
Operator Menu
Operator Menu
GPC3000 BDI = Value
HOURS = Value
SPEED = Value
Hour H1 Runtime 1 = Value Value
H2 Runtime 2 = Value Value
H3 Access 2 = Value Value
Events Last Ev = Value Value
Last-1 Ev = Value Value
Continued on page 84
GPC446
GPC3000
83
ELECTRICAL SYSTEM
Operator Menu
Operator Menu
From page 83
Service Level 2 Password
Level 3 Password
*1)
*1)
Performance SET P1
*1)
SET P2
*1)
SET P3
GPC447
1) Not available on the GPC 3020
GPC3000
84
ELECTRICAL SYSTEM
Service Menu
Service Menu
Analyzer
Analyzer A1 Status A1.1 TRACTION Value
A1.2 HYDRAULIC Value
A1.3 STEER Value
A1.4 MAIN C Value
A1.5 CAN TILLER Value
CAN
A1.6 Value
BACKREST
DISPLAY
A1.7 Value
MODULE
A2 Inputs A2.1 Access 1 Inputs No display
A2.2 Access 2 Inputs See page 88
A2.3 Access 3 Inputs See page 89

Continued on page 86 A2.5 Access 5 Inputs

See page 90
GPC448
GPC3000
85
ELECTRICAL SYSTEM
Service Menu
Analyzer
From page 85
A3 Outputs A3.1 BATTERY % Value
BATTERY
A3.2 Value
VOLTAGE
A3.3 BUZZER Value
A3.4 TRAVEL ALARM Value
A3.5 FAN OUTPUT Value
A3.6 TRAVEL LIGHT Value
BATTERY
A3.7 CURRENT Value
A3.8 SV1 Value
GPC449
GPC3000
86
ELECTRICAL SYSTEM
Service Menu
Analyzer
From page 86
A3.9 SV2 Value
A3.10 PV Value
BRAKE OUTPUT
A3.11 Value
A3.12 HORN OUTPUT Value
TRACTION
A3.13 SPEED Value
RPM TRACTION
A3.14 MOTOR Value
RPM STEER
A3.15 MOTOR Value
Level 3 Only
A4 Test Outputs
GPC450
GPC3000
87
ELECTRICAL SYSTEM
Service Menu
Access 2 Input
From page 85 A2.2.1 RAS SWITCH = VALUE Value
A2.2.1
A2.2.2 LOS
RAS1SWITCH
SW ITCH=
= VALUE
VALUE Value
A2.2.3 RAS 2 + 3 SWITCH= VALUE Value
A2.2.4 LOS 2 + 3 SWITCH= VALUE Value
A2.2.5 LMS 5 SENSOR = VALUE Value
A2.2.10 PRESURE TRANSDUCER = VALUE Value
A2.211 PUMP MOTOR CURRENT = VALUE Value
A2.2.12 PUMP ON= VALUE Value
GPC451
GPC3000
88
ELECTRICAL SYSTEM
Service Menu
Access 3 Input
From page 85 A2.3.1 TEMP ACCESS 3 = VALUE Value
A2.3.2 TS1 = VALUE Value
A2.3.3 FWD SWITCH = VALUE Value
A2.3.4 REV SWITCH = VALUE Value
A2.3.5 POT WPR = VALUE Value
A2.3.6 HSS SWITCH = VALUE Value
A2.3.7 HNS 1 + 2 SWITCH = VALUE Value
A2.3.8 BRS SWITCH = VALUE Value
A2.3.9 FPS 1 SENSOR = VALUE Value
A2.3.10 FPS 2 SENSOR = VALUE Value
A2.3.11 PPCS1 SWITCH = VALUE Value
TRACTION MOTOR CURRENT=

A2.3.15 Value
VALUE
A2.3.16 ECR1 ENCODER 64P = VALUE (pulses) Value
A2.3.17 LMS7 & 7.1 SENSOR1 = VALUE Value
A2.3.18 BLS = VALUE Value
GPC452
GPC3000
89
ELECTRICAL SYSTEM
Service Menu
Access 5 Input
From page 85 A2.5.1 TEMP ACCESS 5 = VALUE Value
A2.5.2 TS3 (TEMP MOTOR) = VALUE Value
A2.5.3 STEER MOT CURRENT = VALUE Value
A2.5.4 STEER POT1= VALUE Value
A2.5.5 STEER POT 2 = VALUE Value
A2.5.6 ECR3 (ENCODER48P) = VALUE Value
A2.5.7 ECR4 (ENCODER48P) = VALUE Value
A2.5.8 STRAIGHT AHEAD SENSOR = VALUE Value
GPC453
GPC3000
90
ELECTRICAL SYSTEM
Service Menu
Test Output
From page 84 A4.1 FN1 Enter to Cancel
(5 second timeout)
The “Test Output” item

can only be reached
through service level 3.
A4.2 SV 1 Enter to Cancel
Currently, only item A4.1
(fan) can be activated.
A4.3 SV2 Enter to Cancel
A4.4 PV Enter to Cancel
A4.5 BRK Enter to Cancel
A4.6 MAIN C Enter to Cancel
A4.7 HN Enter to Cancel
A4.8 Flash Light Enter to Cancel
A4.9 Travel Alarm Enter to Cancel
NOTE
All test outputs are automatically reset after 5 seconds.
Escape
GPC454
GPC3000
91
ELECTRICAL SYSTEM
Service Menu
Calibration
From page 85
FWD/REV
Calibration C1 ROCKER Sure? N Sure? Y
TURN ROCKER MAX FWD &

C1.1 MAX REV, THEN ENTER
Value
Save? N
Save? Y
Steering calibration (see page 93)
C2
C3 LOAD SENSOR Sure? N Sure? Y
C3.1 AQUIRE MIN LOAD CONFIRM
C3.2 AQUIRE MAX LOAD CONFIRM
Save? N
C1
Save? Y
GPC455
GPC3000
92
ELECTRICAL SYSTEM
Service Menu
Calibration
From page 92
C2 STEER SYS Sure? N Sure? Y
C2.1 ACQUIRE TILLER CENTER CONFIRM
C2.2 ADJ FULL RIGHT COARSE VALUE
C2.3 ADJ FULL RIGHT FINE VALUE
C2.4 ADJ FULL LEFT COARSE VALUE
C2.5 ADJ FULL LEFT FINE VALUE
C2.6 ADJ DRIVE TIRE CENTER VALUE
C2.7 2ND ENCORDER ON/ OFF
Save? N
Save? Y
GPC456
GPC3000
93
ELECTRICAL SYSTEM
Service Menu
Features
From page 92
FEATURES F1 LANGUAGE = VALUE ENGLISH
GERMAN
Save? N FRENCH
DUTCH
Save? Y
SPANISH
Re-Key ITALIAN
Required
POLISH
CZECH
DANISH
PORTUGESE
HUNGARIAN
Continued on page 98 FINISH
NORWEGIAN
SWEDISH
RUSSIAN
TURKISH
GREEK
Continued on page 95 SLOVENIAN
GPC457
GPC3000
94
ELECTRICAL SYSTEM
Service Menu
Features
From page 94
F2 TRAVEL ALARM OFF
BOTH
F3 BEACON OFF
REV
KEY
FWD
BOTH
REV
FWD
F4 TRUCK TYPE 3020
*1)
3040
*1)
3060
*1)
TOW
1)
3055
1)
3045
1)
3040-P
F5 Message Mode F5.1 ALL

1)
3055-P
F5.2 SPEED
1)
3045-P
F5.3 HOURS
1)
Continued on page 96 3060-P
F5.4 BDI
GPC458
GPC3000
95
ELECTRICAL SYSTEM
Service Menu
Features
From page 95
USER
F6 PERFORMANCE=VALUE
DISABLE
ENABLE
1)
F7 USER CODES = VALUE DISABLE
ENABLE F7.1 VIEW CODES ENTRY 1 1111 P1
F8 Hour Meter = Value H1
ENTRY 2 2222 P2
H2
ENTRY 3 3333 P3
F9 QUICK PICK OPTION= VALUE NO
ENTRY 25 xxxxPx
YES
F7.2 ADD CODES PIN 0001
1)
PICK POSTION CONTROL OPTION=
F10 VALUE
YES
1)
PERFORMANCE LEVEL P1
NO
1)
F11 FOLD DOWN STEP = VALUE NO 1)
P2
YES
1)
Continued on page 97 P3
F12 KEYLESS = VALUE DISABLE
KEYLESS Value
ENABLE F12.1
TIMEOUT (10-30 min)
GPC459
GPC3000
96
ELECTRICAL SYSTEM
Service Menu
Features
From page 96
F7.3 MODIFY CODES ENTRY 1 PIN 0001
*1)
1)
ENTRY 2 PERFORMANCE LEVEL P1
1)
ENTRY 25 P2
F7.4 DELETE CODES ENTRY 1 1111 P1 1)

P3
ENTRY 2 2222 P2
ENTRY 25 3333 P3
GPC460
GPC3000
97
ELECTRICAL SYSTEM
Service Menu
Hours
From page 94
HOUR H1 Runtime 1 = Value Value 1)
1)
H2 Runtime 2 = Value 1) Value
H3 Access 2 = Value Value 1)
GPC461
1) The setting cannot be changed in service level 2. It can be

increased but not decreased in service level 3.
GPC3000
98
ELECTRICAL SYSTEM
Service Menu
Events
From page 98
EVENTS E1 CHRON HISTORY E1.1 LAST CODE = VALUE VALUE
HOUR = VALUE VALUE
TEMP = VALUE VALUE
E1.2 LAST-1 CODE = VALUE VALUE
HOUR = VALUE VALUE
TEMP = VALUE VALUE
E1.16 LAST-15 CODE = VALUE VALUE
HOUR = VALUE VALUE
TEMP = VALUE VALUE
E2 ACCUM HISTORY EVENT X OCCURENCES = VALUE VALUE
EVENT Y OCCURENCES = VALUE VALUE
EVENT Z OCCURENCES = VALUE VALUE
E3 CLEAR HISTORY E3.1 CLEAR CHRONOLOGICAL NO

YES
E3.2 CLEAR ALL NO
YES
GPC462
GPC3000
99
ELECTRICAL SYSTEM
Service Menu
Performance
From page 99
TRAVEL SPEED FWD

PERFORMANCE P1 1) SET P1 P1.1 EDIT 1 - 9
= VALUE
TRAVEL SPEED REV

P1.2 EDIT 1 - 9
= VALUE
Save? N
ACCELERATION
P1.3 EDIT 1 - 9
= VALUE
Save? Y P1.4 PLUGGING = VALUE EDIT 1 - 9
P1.5 COASTING = VALUE EDIT 1 - 9

Re-Key
Required
QP & WA SPEEDS PF
P1.6 EDIT 1 - 9
= VALUE
P1.7 WA SPEEDS FF = EDIT 1 - 9

VALUE
P1.8 QP COASTING = VALUE EDIT 1 - 9
Continued on page 101 Continued on page 101 P1.9

SPEED CONTROL =
VALUE
EDIT 1 - 9
P1.10 AUX SPEED #1 EDIT 1 - 9
GPC463
GPC3000
100
ELECTRICAL SYSTEM
Service Menu
Performance
From page 100
1) TRAVEL SPEED FWD

PERFORMANCE P2 SET P2 P2.1 EDIT 1 - 9
= VALUE
TRAVEL SPEEDS REV

P2.2 EDIT 1 - 9
= VALUE
Save? N
ACCELERATION
P2.3 EDIT 1 - 9
= VALUE

Re-Key
Required
QP & WA SPEEDS PF
P2.6 EDIT 1 - 9
= VALUE
WA SPEEDS FF =
P2.7 EDIT 1 - 9
VALUE
SPEED CONTROL =
P2.9 EDIT 1 - 9
VALUE
P2.10 AUX SPEED #1 EDIT 1 - 9

Continued on page
GPC464
GPC3000
101
ELECTRICAL SYSTEM
Service Menu
Performance
From page 101
1) TRAVEL SPEED FWD

PERFORMANCE P3 SET P3 P3.1 EDIT 1 - 9
= VALUE
TRAVEL SPEED REV

P3.2 EDIT 1 - 9
= VALUE
Save? N
ACCELERATION
P3.3 EDIT 1 - 9
= VALUE

Re-Key
Required
QP & WA SPEEDS PF
P3.6 EDIT 1 - 9
= VALUE
WA SPEEDS FF =
P3.7 EDIT 1 - 9
VALUE
P3.9 SPEED CONTROL EDIT 1 - 9
Continued on page 103 Continued on page 103 P3.10 AUX SPEED #1 EDIT 1 - 9
GPC465
GPC3000
102
ELECTRICAL SYSTEM
Service Menu
Performance
From page 102
P4 BDI SETTING = VALUE HEAVY PLUS DUTY
HEAVY DUTY
MEDUM DUTY
STANDARD DUTY
LIGHT DUTY
GPC466
GPC3000
103
ELECTRICAL SYSTEM
Service Menu
Performance
From page 104
1) PROP LEVEL PLATFORM =

P5 EDIT 1 - 9
VALUE
PROP OFF RAMP

P6 1) EDIT 1 - 9
PLATFORM = VALUE
1) PROP ON RAMP
P7 PLATFORM = VALUE EDIT 1 - 9
P81) MAX EVP = VALUE EDIT 1 - 9
P91) MIN EVP = VALUE EDIT 1 - 9
P101) PLATFORM LIFT SPEED

EDIT 1 - 9
= VALUE
P111) HIGH FORKS LIFT

EDIT 1 - 9
SPEED = VALUE
PLATFORM
P121) ACCELERATION EDIT 1 - 9
= VALUE
PROP LEVEL HIGH

P13 FORKS = VALUE EDIT 1 - 9
P14 QP & PPC *1) TIME = VALUE EDIT 1 - 9
QP & PPC *1) ACCELERATION

P15 = VALUE EDIT 1 - 9
1)
P16 FPV LOW ON TIME = VALUE EDIT 1 - 9
P17 1) FPV LOW OFF TIME = VALUE EDIT 1 - 9
FORKS LIFT ACCELERATION

P18 1) EDIT 1 - 9
= VALUE
FORKS LIFT DECELERATION

P19 1) = VALUE EDIT 1 - 9
LOAD FACTURY
P20 DEFUALTS EDIT 1 - 9
GPC467
GPC3000
104
ELECTRICAL SYSTEM
Service Menu
Utilities
From page 102

Crown P/N for Display Asm: 139757
UTILITIES U1 Part Numbers U1.1 Access 1 U1.1.1 Module PN=Value Value
U1.1.2 Software PN=Value Value
Crown P/N for Combi AC1: 816300
U1.2 Access 2 U1.2.1 Module PN=Value Value
Crown P/N for Combi AC1: 816300
Crown P/N for EPS AC0: 816301
U1.4.3 Slave Software =Value Value
Crown P/N for CANInterface Molded: 818767

Includes CANInterface PCB: 816590
ACCESS 8
Analyzer (see page 85) U1.5
BACKREST
U1.5.1 Module PN=Value Value
U1.6 ACCESS 8 U1.6.1 Module PN=Value Value

TILLER
GPC468
GPC3000
105
ELECTRICAL SYSTEM
Parameter Setting
Parameter Setting
Parameter Setting for the GPC 3020

The travel and braking patterns of the truck can be
adapted within limits to suit the customer's require-
ments.
Display Description Factory

Setting
Travel Speed FWD Max. forward speed of the unladen truck (battery first). 9
Speeds can be set from 1-9; from 6.0 km/h to 10 km/h.
Travel Speed REV Max. reverse speed of the unladen truck (forks first). 6
Speeds can be set from 1-9; from 6.0 km/h to 10 km/h.
Acceleration Time required in seconds for the unladen truck to accelerate to 8
8.8 km/h.
Settings from 1-9, corresponding to 1.6/1.8/2.0/2.2/2.4/3.0/3.5/4.0/4.5
seconds.
Plugging Time required to brake from 8.8 km/h to 0 km/h when the travel direc- 2
tion is changed (plugging).
Settings from 0-9, corresponding to 0.7/0.8/0.9/1.0/1.1/1.2/1.3/1.4/
1.5/1.6 seconds.
Coasting Time required to brake from 8.8 km/h to 0 km/h when the travel switch 4
is released (coasting). Settings from 1-9, corresponding to 1.3/1.4/1.5/
1.6/1.7/1.8/2.0/2.2/2.4/2.6 seconds.
QP speed PF Max. forward speed of unladen truck in "Quick Pick" mode. Settings 6
from 1-9, corresponding to 2.8/3.2/3.6/4.0/4.4/4.8/5.2/5.6/6.0 sec-
onds.
QP Time Length of time the truck remains in “Quick Pick” mode. 9
Settings from 0-9, corresponding to 1/2/3/4/5/6/7/8/9/10 seconds.
QP Coasting Time the truck takes to decelerate from the pre-set "QP Speed PF" 9
speed to 0 km/h.
Settings from 0-9, corresponding to 0.5/0.7/0.9/1.1/1.3/1.5/1.7/1.9/
2.1/2.3 seconds.
QP Acceleration Time taken for the unladen truck to accelerate from "Quick Pick" for- 1
ward mode to the pre-set “QP speed PF” speed.
Settings from 1-9, corresponding to 1.4/1.6/1.8/2.0/2.2/2.4/2.6/2.8/3.0
seconds.
GPC3000
106
ELECTRICAL SYSTEM
Parameter Setting
Parameter Setting for all Trucks ex-

cept the GPC 3020
The travel and braking patterns of the truck can be
adapted within limits to suit the customer's require-
ments.
Factory Settings
Display Description Perform- Perform- Perform-

ance level ance level ance level
1 2 3
Travel Speed FWD Max. forward speed of the unladen truck (battery
first).
9 9 9
Speeds can be set from 1-9; from 6.0 km/h to
10 km/h.
Travel Speed REV Max. reverse speed of the unladen truck (forks first).
Speeds can be set from 1-9; from 6.0 km/h to 4 4 6
10 km/h.
Acceleration Time required for the unladen truck to accelerate for-
ward to 8.8 km/h.
3 6 8
Settings from 1-9, corresponding to 1.6/1.8/2.0/2.2/
2.4/3.0/3.5/4.0/4.5 seconds.
Plugging Time required to brake from 8.8 km/h to 0 km/h when
the travel direction is changed (plugging).
2 2 2
1.1/1.2/1.3/1.4/1.5/1.6 seconds.
Coasting Time required to brake from 8.8 km/h to 0 km/h when
the travel switch is released (coasting). Settings from
4 4 4
0-9, corresponding to 1.3/1.4/1.5/1.6/1.7/1.8/2.0/2.2/
2.4/2.6 seconds.
QP & PPC Speeds Max. forward speed of unladen truck in "Quick Pick"
PF or “Pick Position Control™" modes. Settings from 1-
6 6 6
9, corresponding to 2.8/3.2/3.6/4.0/4.4/4.8/5.2/5.6/
6.0 km/h.
PPC Speeds FF Max. reverse speed of unladen truck in "Pick Position
Control™" mode. Settings from 1-9, corresponding to 6 6 6
2.8/3.2/3.6/4.0/4.4/4.8/5.2/5.6/6.0 seconds.
QP Coasting Time the truck takes to decelerate from the "QP
Speed PF" speed to 0 km/h.
9 9 9
1.3/1.5/1.7/1.9/2.1/2.3 seconds.
Speed Control Do not change this setting. 3 7 8
AUX Speed #1 Do not change this setting. 1 3 3
GPC3000
107
ELECTRICAL SYSTEM
Parameter Setting
(Continued) Factory Settings

1 2 3
Prop level Platform Percentage opening of the platform lowering valve.

Settings from 1-9, corresponding to 50/51/52/53/54/ 1 1 1
56/57/58/59 percent.
Prop OFF ramp Time taken to stop the platform from its maximum
Platform lowering speed. Settings from 1-9, corresponding to 5 5 5
1.0/1.05/1.1/1.15/1.2/1.25/1.3/1.35/1.4 seconds.
Prop ON ramp Time taken from the start of platform lowering until
Platform maximum lowering speed is reached. Settings from
5 5 5
1-9, corresponding to 1.3/1.35/1.4/1.45/1.5/1.55/1.6/
1.65/1.7 seconds.
Max EVP Maximum opening of proportional valve. Settings
from 1-9, corresponding to 78.4/78.8/79.2/79.6/80.0/
80.3/80.7/81.1/81.5 percent. Increase the setting if 5 5 5
the valve applies late. Decrease the setting if the
valve applies suddenly.
Min EVP Minimum opening of proportional valve. Settings
from 1-9, corresponding to 6.6/7.0/7.4/7.8/8.2/8.6/
9.0/9.4/9.8 percent. Increase the setting if the valve 5 5 5
applies late. Decrease the setting if the valve applies
suddenly.
Platform Lift Speed Platform lift speed measured between LMS6 and
LMS5. Settings from 1 to 9, corresponding to 84/86/ 2 2 2
88/90/92/94/96/98/100 percent.
High Forks Lift Average fork lift speed. Settings from 1-9, corre-
9 9 9
Speed a sponding to 70/75/80/83/85/87/90/95/100 percent.
Platform accelera- Platform acceleration on re-starting after a stop be-

tion tween LMS5 and LMS6. Settings from 1-9, corre-
6 6 6
sponding to 1.4/1.6/1.7/1.8/1.9/2.0/2.1/2.2/2.3 sec-
onds.
Prop level High Maximum opening of "Lower" proportional valve.
Forks b Settings from 1-9, corresponding to 84/86/88/90/92/ 5 5 5
94/96/98/100 percent.
QP & PPC Time Length of time the truck remains in “Quick Pick” or
"PPC" mode.
9 9 9
Settings from 0-9, corresponding to 1/2/3/4/5/6/7/8/9/
10 seconds.
QP & PPC Acceler- Time taken in seconds for the unladen truck to accel-
ation erate in "Quick Pick" or "PPC" mode to the pre-set
forward speed. 1 1 1
2.2/2.4/2.6/2.8/3.0 seconds.
GPC3000
108
ELECTRICAL SYSTEM
Parameter Setting
(Continued) Factory Settings

1 2 3
FPV LOW ON On delay for the "Lower forks" proportional valve.

Time Settings from 1-9, corresponding to 0/5/10/15/20/25/ 1 1 1
30/35/40 percent.
FPV LOW OFF Off delay for the "Lower forks" proportional valve.
Time Settings from 1-9, corresponding to 0/5/10/15/20/25/ 1 1 1
30/35/40 percent.
Forks Lift Accelera- Fork lift acceleration. Settings from 1-9, correspond-
6 6 6
tion ing to 1.4/1.6/1.8/2.0/2.2/2.4/2.6/2.8/3.0 seconds.
Forks Lift Deceler- Fork lift deceleration. Settings from 1-9, correspond-
1 1 1
ation ing to 1.4/1.6/1.8/2.0/2.2/2.4/2.6/2.8/3.0 seconds.
a. Not on the GPC 3055
b. Adjusting this setting has no effect on the GPC 3040 as it does not have a proportional valve.
GPC3000
109
ELECTRICAL SYSTEM
Control Modules
Control Modules Access 2 and Access 3 are located in the same hous-
ing.
The module locations are shown in Components (see
page 110).
Power Fuses
The power fuses are mounted directly on the control-
lers (see Fig. GPC476).
GPC476
1 Access 2 & 3
2 FU7 (400 A), power fuse for Access 2 & 3
3 Access 5
4 FU8 (30 A), power fuse for Access 5
General
Travel, lifting and power steering are controlled by
modules which communicate with each other via a
common CAN-Bus:
• Access 1 (display)
• Access 2 (traction controller, 1 in Fig. GPC476)
• Access 3 (lift controller, 1 in Fig. GPC476)
• Access 5 (steer controller, 2 in Fig. GPC476)
• Acess 8 (CAN interface #1 and #2)
GPC3000
110
ELECTRICAL SYSTEM
Servicing and Replacing the Control Modules
Servicing and Replacing the Con- Replacing Control Modules

trol Modules
Removal
The truck must be de-energised and secured, see
WARNING safety notices. Once this has been done:
Fire risk from short circuits. Control modules oper- 1. Discharge the capacitors.
ate at high currents. Please note:
2. Remove / disconnect all wires (mark the wires if
• You must be trained to carry out this work. necessary). Remove the bus bars if present.
• Use fatigue-free eye protection.
3. Remove the control module mounting screws.
• Wear close-fitting clothing.
4. Remove the control module.
• Do not wear jewelry.
• Always use insulated tools. 5. Check the tooth pattern left by the back plate of the
control module on the assembly plate. The full sur-
face area of the control module must be in contact
WARNING with the plate. If there are any large areas without
direct contact to the controller replace the assem-
bly plate to avoid thermal problems.
Risk of serious injury
Avoid accidents by:
• Switching the truck off. WARNING
• Preventing the truck from being switched on again. structions when handling solvents and lubricants.
• Jacking up the truck and preventing it from rolling 6. Remove the heat conducting paste remains on the
away (see page 15). assembly plate with a lint-free cloth and a commer-
cial silicon removing agent.
Discharging the Capacitors
Assembly
safety notices. Once this has been done: Use a control module with the right software version
(see spare parts manual).
1. Short-circuit the positive and negative connections
of the control module over a resistor (10 - 1. Apply heat conducting paste (Dow Corning® 340,
100 Ohm, min. 5 W) for a few seconds. part no. 053051-008) thin and evenly to the base
plate of the new control module.
2. Attach the control module to the assembly plate.
Servicing the Control Modules
3. If necessary clean the power cable connections.
safety notices. 4. Refit / connect all wires. Attach the bus bars if ap-
plicable.
1. Discharge the capacitors.
5. Set the control module parameters and carry out a
2. Dry clean the outside of the control module. functional test:
3. Check that the nuts attaching the power cables are – Leave the truck jacked up.
tight.
– Connect the battery and remove the power-up
4. Check the logged events. prevention mechanism.
– Adjust the parameters (see page 106).
– Carry out a functional test.
GPC3000
111
ELECTRICAL SYSTEM
Event Codes
Event Codes
Access 2
Event Tool Oper- Description Remedy

Code LED ating
error
LED
200 X - Controller internal error. - Replace controller.

201 X - Memory error. Parameter changes have - Re-load the default settings (attention
been cleared or are no longer stored. - this resets the default settings of all
The truck can operate, but uses the de- the controllers). Service Menu > Per-
fault settings. formance > P20 >
Load Factory Defaults
- If the error persists after switching the
truck off and on again, replace the con-
troller.
202 X - Low voltage on VMN - Replace controller.
203 X - Overvoltage on VMN - Check the power cables for corrosion.
Make sure they are securely attached.
- If the cable attachment is ok, replace
the controller.
204 X - No current to pump motor - Check the power cables for corrosion.
If the pump motor is running but the
error persists, check the current sen-
sor:
- In the service menu > ACCESS2 IN-
PUTS > A2.2.11 > select
PUMP MOTOR CURRENT and check
the reading.
Using a clip-on ammeter measure the
current to the pump motor on the pos-
itive cable.
The two readings should be the same.
- If neither power cables nor the current
sensor circuit are faulty, replace the
controller.
GPC3000
112
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
205 X - Current flow to pump motor without lift - Check the power cables for corrosion.
request. Make sure they are securely attached.
If the pump motor is not running but
the error persists, check the current
sensor:
- In the service menu > ACCESS2 IN-
PUTS > A2.2.11 > select
PUMP MOTOR CURRENT and check
the reading.
Using a clip-on ammeter measure the
current to the pump motor on the pos-
itive cable.
Both readings should be 0 A.
- If neither power cables nor the current
sensor circuit are faulty, replace the
controller.
206 X - Controller temperature too high In the SERVICE LEVEL 3 menu select
ANALYZER MENU > A4.1 > FN1 and
check if the fan has switched on:
- If the fan is not running, check the fan
and its wiring.
If the controller temperature is normal
and the fan is running, the controller
must be faulty:
– Replace controller.
207 X - Pump current intermittently too high Operate the lift again. If the event code
remains:
- Check if the lifting mechanism is slug-
gish or blocked.
- Load too heavy and RV1 relief valve
set too high?
- Pump motor blocked or sluggish due
to faulty bearings?
GPC3000
113
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
216 X - Access 2 has requested a performance In SERVICE MENU > EVENTS >
reduction from Access 3. CHRON HISTORY check the logged
events to ascertain the reason for the
performance reduction.
217 X - Lifting applied during power-up. Release the lift button and start again. If
the message persists:
- Check the connection status of lift
switches RAS, RAS2 and RAS3 in
SERVIVCE_MENU >
ANALYZER MENU >
ACCESS 2 INPUTS > A2.2.1 > and in
A2.2.3. They should not be closed. If
one or more are displayed as being
closed, check the wiring and switches
for damage.
218 X - CAN signal not available. Check wiring to both Access 8 interface
cards in the backrest and the steering. If
the wiring is ok, replace the interface
cards.
219 X - Controller internal error. Replace controller.
220 X - Checksum error Attention: re-loading the default set-
tings will clear all customer-specific set-
tings in all the controllers.
- To restore the default settings: SERV-
ICE MENU > PERFORMANCE > P20
> LOAD FACTORY DEFAULTS and
restart the truck.
- If the error still persists, the controller
must be faulty. Replace controller.
222 X - Lifting is deactivated while Access 2 In the event menu look for entries con-
waits for Access 3. cerning Access 3:
- SERVICE MENU > EVENTS > E1 >
CHRON HISTORY. For Access 3 trou-
bleshooting see page 116.
224 X - Short circuit in PV driver current circuit Disconnect wires from valve coil. Meas-
ure the resistance between GRN/WHT
and batterynegative:
- If the resistance is very low, the control-
ler is faulty. Replace controller.
GPC3000
114
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
226 X - Internal CAN communication inter- Check CAN wiring and connectors.
rupted. Check Access 3 software version:
- SERVICE MENU > UTILITIES >
PART NUMBERS > U1.3 > ACCESS 3 >
U1.3.2 > SOFTWARE PN.
If the error persists despite the wiring be-
ing ok and the software being correct, re-
place the controller.
228 X - One or more drivers (FAN, SV1, SV2, Check FAN, SV1, SV2, ALM, HN, FLS.
ALM, HN, FLS) overloaded.
229 Short circuit in one or more drivers for Disconnect all wires from FAN, SV1,
FAN, SV1, SV2, ALM, HN or FLS. SV2, ALM, HN and FLS. At each con-
nection measure the resistance between
GRN/WHT and batterynegative:
- If the resistance is very low, the control-
ler is faulty. Replace controller.
230 X - Short circuit in FAN, SV1, SV2, ALM, HN If the error occurs when one of the con-
in FLS. sumers is connected then that connector
is the cause:
- disconnect all consumers and meas-
ure their internal resistances. The
rated resistance is 30 Ω. If the resist-
ance is much lower or 0 Ω, the con-
sumer is faulty. Replace consumer.
If the error also occurs when no consum-
ers are connected, the controller is
faulty. Replace controller.
LIFT + - X Lifting and lowering activated simultane- In the SERVICE MENU > select ANA-
LOWER ously. LYZER MENU > ACCESS2 INPUTS >
A2.2.1 RAS SWITCH, A2.2.2 LOS1
SWITCH, A2.2.3 RAS 2+3 SWITCHES,
A2.2.4 LOS 2+3 SWITCHES and check
the connection statuses. If one of the
RAS switches is closed, LOS must be
open. If not, then:
- Check the wiring of the RAS and LOS
switches.
- Test all RAS and LOS switches.
If the wiring and switches are ok but the
error still persists, replace the controller.
GPC3000
115
ELECTRICAL SYSTEM
Event Codes
Event Codes
Access 3

Code LED ating
error
LED

The truck can operate, but uses the de- the controllers).
fault settings. - If the error persists after switching the
troller.
303 X - Controller internal error. - Check the power cables for corrosion.
- If the cable attachment is ok, replace
the controller.
304 X - Overvoltage or low voltage (limits are If the event occurs when the truck is
45 volts and 9 volts respectively). powered up:
- Voltage on PC200-4 drops to below
9 volts. Replace controller.
If the error occurs during travel:
- Check battery condition.
- Check battery cable connections.
- Check main contactor contacts.
305 X - Voltage on VMN too low. If the event occurs when the truck is
powered up:
- Check power cable connections to
motor.
- Check internal motor connections.
- Check motor insulation resistance to
chassis.
If no error is found on the motor, the con-
troller is faulty. Replace controller.
If the event occurs during travel:
- Check motor connections.
- Check main contactor contacts.
chassis.
If no error is found on the motor or main
contactor, the controller is faulty. Re-
place controller.
GPC3000
116
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
306 X - Voltage on VMN too high. If the event occurs when the truck is
powered up:
- Check power cable connections to
motor.
- Check internal motor connections.
If the event occurs when the main
contactor is closed:
- Check motor connections.
chassis.
307 X - Main contactor already closed. - Check freedom of movement of main
contactor contacts.
- Test if main contactor power cable has
shorted.
308 X - Main contactor does not close. - Check main contactor wiring.
- Measure voltage on coil connections:
It should be approx. 24 volts measured
between the red/white wires and the
battery negative terminal.
- Check freedom of movement of main
contactor contacts.
309 X - Controller internal error. - Switch the truck off and on again. If the
error persists, replace the controller.
310 X - Controller capacitors do not charge. - Check whether additional electrical
consumers have been connected with-
out Crown's permission. If so, discon-
nect these consumers and start the
truck. If the error persists, replace the
controller.
314 X - Main contactor driver shorted. - Check for short circuit or low imped-
ance between CA200-17 and bat-
terynegative. If there is no error in the
wiring, replace the controller.
GPC3000
117
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
315 X - Main contactor driver - Measure voltage on the main contac-

tor coil connections: It should be ap-
prox. 24 volts measured between the
red/white wires and the battery nega-
tive terminal.
- Check main contactor wiring for dam-
age.
If the main contactor and its wiring are
ok, replace the controller.
316 X - Main contactor coil and/or brake coil - Check wiring for brake and main con-
shorted. tactor.
- Disconnect the main contactor and
measure the coil resistance: It should
be R25 °C=44 Ω.
- Disconnect the brake and measure the
coil resistance: It should be
R25 °C=10 Ω.
If no error is discovered in the wiring, the
main contactor or the brake, then the
controller is faulty. Replace controller.
317 X - VACC error - Check if the traction potentiometer re-
sets itself to 0 volt output voltage in
neutral: Service Menu > Analyzer >
Acess 3 Inputs > A2.3.5 > POT WPR.
- To calibrate the potentiometer: Service
Menu > Calibration Menu > C1 > FWD/
REV ROCKER
319 X - Load sensor error - To check the load sensor: Service
Menu > Analyzer > Access 2 Inputs >
A2.2.10 > Pressure Transducer. When
the truck is unladen the reading should
be 1 volt. For a truck laden to maxi-
mum capacity the reading should be at
least 10 volts.
- If the readings do not match, re-cali-
brate the load sensor.
- If the load sensor cannot be re-cali-
brated, replace the load sensor and re-
calibrate.
- If a new load sensor does not remedy
the situation, then the controller must
be faulty. Replace controller.
GPC3000
118
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
320 X - No CAN Bus communication between - Switch off the truck and measure the
controller and display. resistance on connector CA200 be-
tween pin 1 and pin 2: It should be
R=60 Ω.
- Check connector on display.
- Check that the display is working cor-
rectly.
321 X - Truck model not selected. Warning: Only select GPC3020 if it is in
fact the correct truck model. The setting
cannot be reversed.
- In the service menu display select >
Features Menu > F4 > Truck Type and
adjust.
322 X - Short circuit from positive brake connec- - Measure voltage from CA200-7 after
tion after battery+. batterynegative. If the voltage is 0 V,
there is a short circuit between the
positive brake connection and PC300-
20 on the controller. Remove pin
PC300-20 temporarily: If the error still
persists, the controller must be faulty.
Replace controller.
330 - PPCS error - Check switch in Analyzer menu: Serv-
ice Menu > Analyzer Menu > Access 3
Inputs > A2.3.11 - A2.3.14
If the truck is idle:
A2.3.11 = A1, A2.3.12 = A3, A2.3.13 =
A5, A2.3.14 = A7
334 X - Controller still in system test phase. - The event deletes itself after the sys-
tem test.
GPC3000
119
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
335 X - CAN communication with Access 2 (hy- - Check software version: SERVICE
draulic controller) failed. MENU > UTILITIES > U1 > U1.2 >
ACCESS 2 > U1.2.2 SOFTWARE PN
- If the software version is correct, the
controller must be faulty. Replace con-
troller.
338 X - Incorrect battery voltage - Check the battery voltage:
SERVICE MENU > ANALYZER > A3 >
OUTPUTS > A3.2 BATTERY VOLT-
AGE.
- Measure the battery voltage directly on
the battery terminals.
- If the voltages differ, replace the con-
troller.
340 X - Unsuitable parameter setting for drive Attention: re-loading the default set-
motor. tings will clear all customer-specific set-
tings in all the controllers.
- To restore the default settings: SERV-
ICE MENU > PERFORMANCE > P20
> LOAD FACTORY DEFAULTS and
restart the truck.
341 X - Brake driver has shorted. - Check for short circuit or low imped-
ance between CA200-31 and bat-
terynegative.
- Remove wire from PC200-31 tempo-
rarily. If the error persists, there will be
a short circuit in the wiring. If the error
message disappears, the controller is
faulty.
GPC3000
120
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
342 X - Forward and reverse travel commands - In the service menu > Analyzer > Ac-
applied simultaneously. cess 3 Inputs > A2.3.3 and A2.3.4
check the connection status. Both
should be OFF. If not, then:
- Check the direction switch connection
on the CAN interface: CA204-4 and -5
should have 0 volts. If you record a
voltage, check the plug connectors for
damage and the wiring for errors. If no
errors are detected, the fault lies with
the X10™ control handle:
- Check the CAN interface in the X10™
control handle. To do this remove pins
CA204-4 and -5 from the connector.
Then in the service menu > Analyzer >
Access 3 Inputs > A2.3.3 and A2.3.4
check the connection status. Both
should be OFF. If not, replace the CAN
interface in the X10™ control handle. If
the error persists with the new inter-
face and pins CA204-4 and -5 re-
moved, the controller must be faulty.
Replace the controller.
343 X - Encoder error ECR M1 - Check encoder wiring and plug con-
nectors for corrosion. Make sure they
are firmly attached and check for trap
points. If no errors are detected, the
fault lies with the drive motor sensor
bearing.
- Either fit a new traction motor or dis-
mantle the drive motor and replace the
sensor bearing.
GPC3000
121
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
344 X - Brake switch control error. - In the service menu check> Analyzer >
This error occurs if the CAN input is "ON" Access 3 Inputs > A2.3.8 > BRS
and the hard-wired input CA200-33 on Switch A2.3.8. When the brake switch
the controller is “OFF”. (The hard-wired is not pressed, the input should be
input signal acts as a breakdown insur- "ON". If it is “OFF”, remove pin 33 from
ance - it conducts battery voltage pro- CA200 and measure between the pin
vided the brake switch is not depressed.) and the batterynegative terminal. Bat-
tery voltage should be present. If not,
remove pin A1 from CA204 and meas-
ure between the pin and the bat-
terynegative terminal. Battery voltage
should be present. If not, then either
the brake switch or the wiring between
CA410-2 and CA204-A1 is faulty. If
battery voltage is present, then the
CAN interface is faulty. Replace inter-
face.
- If A2.3.8 is "ON", then the CAN inter-
face is faulty. Replace interface.
345 X - Brake switch control error. (As for event - In the service menu view> Analyzer >
code 344, except that in this case input Access 3 Inputs > A2.3.8 >
CA200-33 is “ON” and the CAN signal on BRS Switch. When the brake switch is
the input is "OFF". not pressed, the input should be "ON".
If it is “OFF”, remove pin 33 from
CA200 and measure between pin 33
and the batterynegative terminal. Bat-
tery voltage should be present. If not,
remove pin A1 from CA204 and meas-
ure between the pin and the bat-
terynegative terminal. Battery voltage
should be present. If not, then either
the brake switch or the wiring between
CA410-2 and CA204-A1 is faulty. If
battery voltage is present, then the
CAN interface is faulty. Replace inter-
face.
- If A2.3.8 is "ON", then the CAN inter-
face is faulty. Replace interface.
GPC3000
122
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
347 X - Encoder ECR M1 blocked. - Overload by the operator (blocked

(This error occurs if a travel request has drive wheel caused by ground uneven-
been issued for 15 seconds but the en- ness or trying to push a heavy load).
coder does not turn.) - Error in drive motor sensor bearing. Ei-
ther fit a new drive motor or dismantle
the drive motor and replace the sensor
bearing.
348 X - Parking brake too weak to maintain the - Repair brake (see page 145).
truck safely.
GPC3000
123
ELECTRICAL SYSTEM
Event Codes
Event Codes
Access 5

Code LED ating
error
LED

The truck can operate, but uses the de- the controllers.): SERVICE MENU >
fault settings. PERFORMANCE > P20 > LOAD FAC-
TORY DEFAULTS
- If the error persists after switching the
troller.
507 X - Open the main contactor. Access 3 has not closed the main con-
tactor in 1.5 seconds:
- In the SERVICE MENU check >
EVENTS > E1 > CHRON HISTORY
events triggered by Access 3.
- For troubleshooting see event
code 306, page 117.
Steering - X Access 5 heatsink temperature above - Test the fan: Service Level 3 > Ana-
control- 75 °C. lyzer Menu > A4.1 > FN1. Replace the
ler hot fan if faulty.
- Check the air duct and fan for
contamination and foreign bodies.
Clean if necessary.
- Check Access 5 temperature: If the
controller is not hot, the air duct clean
and free of foreign bodies and the fan
is working, the controller must be
faulty. Replace controller.
GPC3000
124
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
Steer mo- - X Motor temperature in the coils above - Check steer motor temperature sen-
tor hot 150 °C. sor: R20 °C = 581 Ω and R120 °C =
1227 Ω. If the sensor is faulty, repair or
replace the motor.
- If the motor temperature is normal and
the sensor is not defective, then the
controller must be faulty. Replace con-
troller.
510 X - Phase V does not conduct current. - Check fuse FU8.
- Check power cable connections with
controller, voltage present between B+
and B- on controller?
If there is voltage present and the wiring
is ok, replace the controller.
511 X - Phase U does not conduct current. - Check fuse FU8.
512 X - Phase W does not conduct current. - Check fuse FU8.
513 X - Channels A & B swapped on encoder - Replace CA203-7 and CA202-8.
ECR1.
GPC3000
125
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
514 X - Steer sensor signal interrupted. - This error can occur temporarily due to
a major impact on the truck. Restart
the truck.
- If the error persists after restarting the
truck, check the wiring:
Measure the voltage between CA220-
4 and CA220-2 while moving the steer-
ing to the left. The voltage should drop
from 2.5 V to 0.5 V. If it does not, then
either the wiring or the steer sensor is
faulty. Replace the steer sensor.
If ok, then measure the voltage be-
tween CA220-3 and CA220-2 while
moving the steering to the right. The
voltage should rise from 2.5 V to 4.5 V.
If it does not, then either the wiring or
the steer sensor is faulty. Replace the
steer sensor.
515 - X Steering hazard. - The message is reset as soon as the
The steering has applied and intercepted steering reverts to neutral.
a steering angle which was too exces-
sive for the current speed.
516 X - Safety relays in the controller have not - Check wiring between CA201-4 and
closed. CA200-7.
- Disconnect CA201 and measure the
voltage on pin 4 of the connector. If the
voltage is >12 V and there is no short
circuit in the wire, the problem lies with
Access 3.
- Check Access 3 event codes.
GPC3000
126
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
517 X - In idle and with the steering in neutral the - Check encoder ECR1. To do this, in
SAHS (Straight Ahead Sensor) continu- the service menu select > Analyzer
ally switches On/Off. Menu > Access 5 Inputs > A2.5.6 &
A2.5.7 > ECR1:
With the steering turned as far to the
right as possible, the reading should
be 4.5 V.
With the steering turned as far to the
left as possible, the reading should be
0.5 V.
With the steering in neutral (straight
ahead), the reading should be 1.8 V -
3.2 V.
If the readings are out of range, re-
place ECR1.
- To check the SAHS:
Turn the steering to the right, the sen-
sor LED should be permanently off.
Turn the steering to the left, the sensor
LED should be permanently on. If the
LED is not permanently on/off respec-
tively, check the edge of the cam on
the gear unit for possible build-up of
conductive contamination. Clean if
necessary.
- Check the screw-in depth of the
SAHS: it should be 2.5 mm above the
top edge of the cam.
- If none of the above problems is the
cause, replace the controller.
523 X - Steer motor blocked. (The maximum cur- - Check if the drive wheel is blocked
rent is drawn for more than 1 second). (e. g. if it is stuck in a hole).
- Check if motor wiring has shorted.
- Check motor insulation resistance.
GPC3000
127
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
525 X - Feedback sensors (ECR1 & ECR2) do - Check if the drive wheel is blocked
not change value when the steer sensor (e. g. if it is stuck in a hole).
output level changes. - Check if the steer sensor is physically
jammed.
- If the steer motor was replaced before,
check the motor direction of turn. If it is
turning the wrong direction, the power
cable connections have been
swapped.
526 X - The steer sensor has an unstable output - Check if the steer sensor is physically
voltage (fluctuations >0.3 V in less than jammed.
16 ms). - Replace the steer sensor.
530 X - Position error. Steer sensor and feed- - Check if the steer sensor is physically
back encoder (ECR1) give different posi- jammed. Check wiring for a short cir-
tions. cuit. Check if the connector is correctly
positioned.
- If the steer sensor is ok: Check if the
drive wheel is blocked (e. g. if it is
stuck in a hole). If this is also not the
case, replace encoder ECR1 (or the
entire steer motor).
531 X - Access 3 parameter list cannot be read. - Check CAN Bus between Access 3
Steering not operational. and Access 5:
Switch off the truck and measure the
resistance between CA210-1 and
CA210-2. It should be = 60 Ω.
- Leave the truck switched off and dis-
connect CA201. Measure the resist-
ance between CA201-A14 and
CA201-A6. It should be = 120 Ω. If not,
then replace the controller.
GPC3000
128
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
532 X - Steering controller cannot align the drive - Check wiring of the SAHS and the con-
wheel when the truck is switched on. nector for damage.
- In the service menu > Analyzer Menu
> Access 5 inputs > A2.5.8 Straight
Ahead Sensor check the connection
status of the SAHS. The connection
status should change for a +/- 10°
steering demand (this can be ob-
served directly on the LED of the
SAHS).
- Check the edge of the cam on the gear
unit (by removing the SAHS) for possi-
ble build-up of conductive contamina-
tion. Clean if necessary.
- If the error persists, replace the SAHS.
533 X - An error in Access 3 prevents the two - Check Access 3 event codes:
safety relays in Access 5 from closing. Service Menu > Events > E1 >
The steering controller remains switched CHRON HISTORY
off.
534 X - Frequency of feedback encoder ECR1 is - Software version error. In the SERV-
out of range. ICE MENU > UTILITIES > U1 > U1.4 >
ACCESS 5 > U1.4.2 >
SOFTWARE PN check the version
number.
- Check wiring of ECR1 and ECR2.
- If the software version is correct and
the wiring is ok, replace encoder ECR1
(or the entire steer motor).
536 X - Data request takes too long. - Switch the truck off and on again.
GPC3000
129
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
538 X - CAN Bus communication between - Check CAN Bus between Access 3
Access 5 and Access 3 failed for more and Access 5. To do this, switch the
than one second. truck off:
Disconnect CA210 and measure the
resistance between CA201-A14 and
CA201-A6. It should be = 120 Ω.
CA200-42. It should be = ∞.
- Disconnect CA205 and CA207. Meas-
ure the resistance on both interface
cards between pins B1 & B4. It should
be = ∞.
540 X - Position error between encoder ECR1 - Check ECR1 wiring and connector.
and SAHS. - In the service menu select > Analyzer
> A2 > Access 5 Inputs > A2.5.6 and
turn the steering to the right. This
should increase the reading. If not, re-
place encoder ECR1 (or the entire
steer motor).
- In the service menu > Analyzer Menu
> Access 5 inputs > A2.5.8 Straight
Ahead Sensor check the connection
status of the SAHS. The connection
status should change for a +/- 10°
steering demand (this can be ob-
served directly on the LED of the
SAHS).
- Check the edge of the cam on the gear
unit (by removing the SAHS) for possi-
ble build-up of conductive contamina-
tion. Clean if necessary.
- If the error persists, replace the SAHS.
- If the error still persists, replace
Access 5.
GPC3000
130
ELECTRICAL SYSTEM
Event Codes

Code LED ating
error
LED
544 X - Safety relay KM (internal) closed but - Check wiring from CA201-4 and
should be open. CA201-5 to CA200-7 for a short circuit.
- Switch off the truck and disconnect
CA201. Measure the resistance be-
tween CA201-4 and CA201-5. It
should be = ∞. If not, replace
Access 5.
545 X - Safety relay KS (internal) closed but - Check wiring from CA201-4 and
should be open. CA201-5 to CA200-7 for a short circuit.
- Switch off the truck and disconnect
CA201. Measure the resistance be-
tween CA201-4 and CA201-5. It
should be = ∞. If not, replace
Access 5.
GPC3000
131
ELECTRICAL SYSTEM
Drive Motor
Drive Motor NOTE

See Fig. GPC412, page 134) Take care not to damage the toothing of the pinion (68)
in the process.
Drive Motor Disassembly 3. When positioning, engage the toothing of the pin-
ion (68) with the drive pinion in the gear unit.
1. Switch off the truck and disconnect the battery.
4. Fit the tie rod (79) and torque it to 16 Nm.
2. Prevent the truck from being switched on again
5. Attach the retaining ring (82), supporting ring (81),
and rolling away.
brake carrier and key (73) of the rotor (72).
3. Undo all the connections on the drive motor and
6. Assemble the brake (see page 148)
the brake.
7. Fit the retaining plate (85) to the bearing plate (78).
4. Open the strain relief to remove the steering trans-
mission connector from the retaining plate (85) (on 8. Fit the terminal board and torque the screws to
the drive motor). 10 Nm.
5. Remove the brake (see page 148). 9. Fit the drive system connector to the retaining plate
(85) and screw on the strain relief.
6. Remove the retaining ring (82), supporting ring
(81), brake carrier and key (73) of the rotor (72). 10. Connect the motor and brake and test them.
7. Unscrew the retaining plate (85) from the bearing
plate and remove it.
8. Remove the tie rod (79).
NOTE
An eye bolt can be fitted to the thread at the rotor end
to lift out the rotor assembly.
9. Lift out the entire rotor assembly with the B bearing
plate while removing the sensor bearing wire from
the rubber socket.
10. Lift out the frame and field (65).
Drive Motor Assembly

1. Assemble the frame and field (65) in the correct
position.
NOTE
An eye bolt can be fitted to the thread at the rotor end
to position the rotor assembly.
2. Position a new or the repaired rotor assembly com-
plete with the B bearing plate:
– To do this, place the sensor bearing wire in the
rubber socket and fit the rubber socket into the
opening of the B bearing plate.
GPC3000
132
ELECTRICAL SYSTEM
Drive Motor
Repairing the Drive Motor 3. Insert shims (87) and the retaining ring (74).
4. Press the rotor shaft (72) into the sensor bearing
while supporting the inner ring of the sensor bear-
CAUTION ing.
Repairing the drive motor requires special tools such 5. Insert the retaining ring (80).
as a hydraulic press, suitable extractors and in-house
On the A side (gear unit side):
produced assembly aids.
If you do not have these tools then use pre-assembled 1. Press the ball bearing (70) onto the rotor while sup-
assemblies (see GPC 3000 Series Parts Manual). porting the rotor.
2. Insert the retaining ring (69).
NOTE
3. Press on the centrifugal disc (86) while supporting
If repairing, replace all bearings and seals. the rotor.
4. Insert the key (71).
Preparation
5. Press the pinion (68) onto the rotor while support-
1. Remove the drive motor. ing the rotor.
2. Bring the rotor assembly and B bearing plate onto 6. Slide on the shim (67) and insert the retaining ring
a workbench. (41).
Dismantling the Rotor Assembly Final task:

On the A side (gear unit side): 1. Assemble the drive motor (see page 132).
1. Remove the retaining ring (66) and shim (67).
2. Remove the pinion (68) using a suitable extractor.
3. Remove the key (71).
4. Pull off the centrifugal disc (86) and remove the re-
taining ring (69).
5. Remove the ball bearing (70) using a suitable ex-
tractor.
On the B side (brake side):
1. Remove the retaining ring (80).
2. Press the rotor shaft (72) off the sensor bearing
(75).
3. Remove the retaining ring (74) and shims (87).
4. Remove the sensor bearing (75) from the bearing
plate (78).
5. Remove the shims (77) and O ring (76).
Assembling the Rotor Assembly

On the B side (brake side):
1. Place the shims (77) and a new O ring (76) into the
bearing plate (78).
2. Fit a new sensor bearing (75) into the bearing plate
(78) while noting the orientation of the connector.
GPC3000
133
ELECTRICAL SYSTEM
Steer Motor
Steer Motor
84
83 52 1
85 18 2
53
82 19
81 3
80 54 20 4
57
79 55 21
5
22
78 56
6
77 23
24
76
75 7
58
87 25
59
74 26
73 27
28 8
60 9
61 10
12 13
72 64 62 11
63 29
30
88 14
31
32 15
71
16
33
70
17
69 34 35
86 36
37 38 39
68 40 41
67
66
45
44
46
65 42
47
43
48
49 51
50
GPC412
GPC3000
134
ELECTRICAL SYSTEM
Steer Motor
Special Tools Required Preparation

To remove and assemble the steer motor: 1. Disassemble the steer motor.
• Tool for the tie rod (part no. 822672). Steer Motor Disassembly
• Hydraulic press and suitable supporting equipment 1. Remove the sensor bearing (8) using a suitable ex-
for pressing on components. tractor.
2. Remove the frame and field (6).
Steer Motor Disassembly 3. Remove the retaining ring (3).
See Fig. GPC412, page 134) 4. Press the rotor (7) off the sensor bearing (4).
2. Undo all connections from the steer motor.
3. Open the strain relief to remove the steering trans- CAUTION
mission connector from the retaining plate (85) (on
the drive motor). The pinion (17) and rotor (7) must not be used again
after disassembly.
4. Disassemble the tie rod (1) using the special tool
(part no. 822672). 5. Pull the pinion (17) off the rotor (7) and dispose of
both parts.
5. Lift the steer motor, complete with B bearing plate
and frame and field, from off the end cap (24). 6. Remove the retaining ring (5).
7. Remove the sensor bearing (4) from the bearing
plate (2).
Steer Motor Assembly
1. Fit the steer motor, complete with B bearing plate Steer Motor Assembly
and frame and field, onto the end cap (14).
1. Press a new sensor bearing (4) into the bearing
2. Attach the tie rod (1) and using the special tool plate (2).
(part no. 822672) torque it to 1.8 Nm.
2. Fit the retaining ring (5).
3. Attach the drive system connector to the retaining
plate (85). 3. Press a new pinion (17) into the new rotor (7).
4. Screw on the strain relief firmly. 4. Press the rotor (7) into the sensor bearing (4) while
supporting the inner ring of the sensor bearing.
5. Connect the steer motor.
6. Position the frame and field (6).
7. Press on a new sensor bearing (8) with a suitable
Repairing the Steer Motor bushing while supporting the rotor (7).
8. Fit a new O ring (9) into the groove of the sensor
CAUTION bearing (8).
Repairing the steer motor requires special tools such

as a hydraulic press, suitable extractors and in-house
Final task:
produced assembly aids. 1. Assemble the steer motor.
If you do not have these tools then use pre-assembled
assemblies (see GPC 3000 Series Parts Manual).
NOTE
If repairing, replace all bearings and seals.
GPC3000
135
ELECTRICAL SYSTEM
Pump Motor
Pump Motor • If oil or grease is found in the motor collector com-

partment (usually a paste consisting of oil, oil va-
pour, dust and carbon particles), immediately re-
General Maintenance Instructions move the cause and clean the motor thoroughly:
These maintenance instructions apply to all DC – Oil or grease burns in the brush sparks and
motors with brushes. leaves behind a highly abrasive oil ash which
can very quickly destroy the collector and the
brushes.
WARNING
• The brushes must be able to move freely in the
Risk of serious injury! brush support (without spring tension) without tilt-
Avoid accidents by: ing. Never modify the brushes if one or more can-
not move freely. In this case replace all brushes as
• Switching off the truck. they will probably have been thermally overloaded.
• Disconnecting the battery. Thermal overloading causes the brushes to swell
• Preventing the truck from being switched on again. up. Brushes which jam in the brush support pro-
duce intense sparking and destroy the collector.
away. • The brush edges must not be cracked. Brushes
For further details refer to the Safety chapter. with cracking along the long edge of the surface
will have been damaged by a worn collector. If in-
Maintenance Instructions formation is provided in the manual, restore the
collector to the specified limits. Otherwise, replace
• Remove all brushes and check for wear. If one or the armature in full.
more brushes need to be replaced, replace all
brushes at the same time. In addition to the • Loose brush connections are a clear sign of motor
brushes the pressure springs must also be re- overload. In this case inspect the collector for burn-
placed to ensure the correct pressure. ing and repair or replace as necessary.
The length of the shortest brush determines whether • When fitting the brush take care to place the spring
the brush set needs to be replaced. gently on the brush. If the contact is too hard the
The brushes should be replaced even if they have not brush will be damaged.
worn down to the minimum length. Their remaining
useful life could be much shorter than the time until the
• Make sure that all brushes contact the armature
with the same pressure.
next inspection.
– If a brush is too short the spring will lie on the • New brushes must be run in with a medium load in
brush support and there will be no pressure. the first hours. Never fully charge the motor
The brush will spark during operation, burning straight away.
the collector with consequential damage.
• Blast the motor with dry compressed air only.
• Check the armature for unevenness, burning,

1.2 kW Pump Motor
grooves and cracking of the multi-plate edges. The GPC 3020 and 3040 models are fitted with this
Turn the armature if necessary. A non-oily, evenly motor.
distributed layer on the brush surfaces is normal.
Brushes
WARNING 1. Disconnect the battery.
Health risk. Observe the manufacturer’s safety in- 2. Prevent the truck from rolling away.
structions when handling solvents and lubricants. 3. Unscrew the commutator bearing lid and remove
the insulating protective cap.
GPC3000
136
ELECTRICAL SYSTEM
Pump Motor
4. Apply dry compressed air to the motor.

5. Remove and check the carbon brushes (see
page 136):
– Length of a new carbon brush: 20 mm
– Carbon brush wear limit: 10 mm
Armature
1. Check the armature (see page 136).
New armatures have a 40 mm diameter. The wear limit
is 38.3 mm.
NOTE
Do not over tighten the armature. Replace it if the wear
limit has been reached.
2.2 kW Pump Motor

The GPC 3045. 3055 and 3060 models are fitted with
this motor.
Brushes
1. Disconnect the battery.
2. Prevent the truck from rolling away.
3. Remove the tensioning belt from the pump motor.
4. Apply dry compressed air to the motor.
5. Remove and check the carbon brushes (see
page 136):
– Length of a new carbon brush: 23 mm
– Carbon brush wear limit: 15 mm
Armature
1. Check the armature (see page 136).
New armatures have a 45 mm diameter. The wear limit
is 4 mm.
NOTE
Do not over tighten the armature. Replace it if the wear
limit has been reached.
GPC3000
137
ELECTRICAL SYSTEM
Battery
Battery
General
The condition of the battery has a considerable impact
on the performance of the truck. Optimum mainte-
nance is key to maintaining the performance and useful
life of the battery.
Charging the Battery
NOTE
The battery must be serviced and charged strictly
in accordance with the battery and charger manu-
facturers' instructions.
Unsuitable chargers and incorrect maintenance will re-
sult in reduced truck performance in the short term. In
the medium term it will lead to premature battery fail-
ure.
Replacing the Battery
DANGER
Incorrect battery sizes and weights can result in fa-
tal accidents.
Incorrect weight and dimensions alter the truck's centre
of gravity.
Only use batteries with the right dimensions, weight
and capacity requirements for this truck.
1. Replace the battery as outlined in the truck opera-
tor manual.
GPC3000
138
ELECTRICAL SYSTEM
Contactors
Contactors Springs
Always replace springs if:
• New contacts are being fitted.
• If the springs show signs of corrosion or decolour-

ing caused by overheating.
M1480
WARNING
Short circuits can cause fires.
Before working on the contactors disconnect the bat-
tery from the truck.
Inspection
Contacts
The contacts can blacken, swell and roughen during
normal operation. This is normal, and there is no need
to file or polish them. On the contrary: mechanically re-
worked contacts burn out very rapidly.
Under certain conditions the contact silver coating can
wander from one contact to another, where it can build
up. This is quite harmless. The contacts must only be
replaced if the silver coating has flaked off to such an
extent that the supporting metal is visible.
Coils
The coil cannot be repaired. Replace the coil if faulty.
The coil is faulty if using an ohmmeter between the
connections you measure either an endless resistance
or no resistance.
GPC3000 4-3400
139
ELECTRICAL SYSTEM
Contactors
Servicing
CAUTION
Only use original Crown contactors as replacements, 6
or Crown spare parts for repairs.
The contactors are specially made for the truck.
Do not change the place or the angle where they are
positioned, and do not change the wiring. 1
When disassembling a contactor for inspection or re-
pairs, mark out the position of the contacts with respect
to each other. It is important that contacts that are al- 5
ready been worked into each other are reassembled
together. Otherwise, excessive wear and premature
failure will result. 4
NOTE
This contactor has fixed contacts that are connected to
the cover. As contacts must always be replaced in
pairs, for servicing you need a complete cover, 2 mov-
ing contacts and 2 contact springs. 2
Dismantling
3
(see Fig. MS-3400-031)
1. Unscrew two mounting screws (6) and remove the
upper housing section (5).
2. Pull out the moving contact (2).
3. Unscrew the mounting nuts and take off the fixed
MS-3400-031
contacts (1).
4. Clean, check and if necessary replace the compo- 1 Contact, fixed
nents. 2 Contact, moving
3 Coil
Assembly 4 Contact spring
1. Carefully insert the moving contact into the holes 5 Housing upper section
provided. 6 Screw
2. Reverse disassembly procedure for assembly.

3. Screw in and tighten the mounting screws with
sealant 053050-006.
4-3400 GPC3000
140
ELECTRICAL SYSTEM
Controller Safety Test (PMT)
Controller Safety Test (PMT) Testing Access 2

(HCM) (COMBI AC1)
General General
EN 1175-1 requires regular testing of the safety circuits In the following test the power output -P of Access 2 is
for the controllers used. shorted against the -B connection of the controller.
The test is a "Pulse Monitor Trip Test”, or PMT for short. 1. Switch off the truck if it is switched on.
Trucks whose controllers fail the PMT may not be
operated. They must be repaired immediately.
Required tools
• A test wire, approx. 500 mm long with a 1 mm2 Access 2 / Access 3
cross section. The wire must have a 10 A fuse and
10
-B
A
testing terminals at both ends.
Carrying out the PMT

-P
DANGER
+ BF FU 7 +
You or other people could be fatally injured. + + M2
400A
The truck may start accidentally. Jack up the truck so
that the drive wheel is clear of the ground before carry-
ing out any work on the electrical system. GPC481
1. Switch off the truck and disconnect the battery. 2. Connect the test wire to -B and the -P connection.
2. Jack up the truck (see page 15) so that the drive 3. Switch on the truck:
wheel is clear of the ground. – The traction motor should not start up.
3. Connect the battery. – The display should read EV = 310.
4. Switch off the truck.
5. Disconnect the battery and remove the test wire.
7. Test the truck's functions.
If the truck is functioning normally, test Access 3.
Testing Access 3
(TCM) (COMBI AC1)
General
In the following test phases U, V and W of the Access 3
power part are successively shorted against the -B
connection of the controller.
Performing the test

1. Switch off the truck if it is switched on.
GPC3000
141
ELECTRICAL SYSTEM
Controller Safety Test (PMT)
Access 2 / Access 3 Access 5
W W
W W
V
V M1 V
V M3
U 3 U 3
U AC U AC
-B -B
- -
A A
10 10
GPC480 GPC480
2. Connect the test wire to -B and the U connection 2. Connect the test wire to -B and the U connection.
(see Fig. GPC480).
3. Switch on the truck:
3. Switch on the truck:
– The steering and traction motor should not
– The traction motor should not start up. start.
– The display should read EV = 326. – Lifting should be enabled.
4. Switch off the truck. – The display does not show an event code.
5. Disconnect the battery and remove the test wire. 4. Switch off the truck.
6. Connect the battery. 5. Disconnect the battery and remove the test wire.
7. Test the truck's functions. 6. Connect the battery.
If the truck is functioning normally, repeat the test with 7. Test the truck's functions.
the test wire between -B and the V and W connections
If the truck is functioning normally, repeat the test with
respectively.
the test wire between -B and the V and W connections
respectively.
Testing Access 5
(SCM)
General
In the following test phases U, V and W of the Access 5
power part are successively shorted against the -B
connection of the controller.
1. Switch off the truck if it is switched on.
GPC3000
142
BRAKE SYSTEM
143
Notes:
144
BRAKE SYSTEM
Electromechanical Brake
Electromechanical Brake 5. Use a feeler gauge to measure the air gap between
the brake lining (2) and the armature disk (1).
Repaire the brake if the air gap is > 0.5 mm. The air
General gap cannot be adjusted, a wear part kit is available
The electromechanical brake is only activated when: (see spare parts catalog).
The wear part kit consists of the following:
• The truck is idle (automatically through the traction
controller). – Friction plate
• When the Emergency Disconnect is pulled. – Brake disk

– Elastic band and 2 screws to aid installation
It acts as a parking brake and become an emergency
and to secure during transport.
brake as soon as the Emergency Disconnect is pulled.
It is not used as a service brake and is therefore virtu-
ally wear-free.
The drive motor is used as a service brake in regener-
ative mode.
Servicing the Brake

Servicing is limited to checking the air gap every 1000
service hours.
Measuring the air gap
2
GPC407
The brake is mounted on the drive motor.

1. Switch off the truck and disconnect the battery.
2. Remove the panel.
3. Remove the dust shield ring (3, Fig.GPC407).
4. Apply weak pressurized air to the abrasion.
GPC3000
145
BRAKE SYSTEM
Replacing the Brake
1
2
3
4
10 1
1
A
9
GPC409
6. Attach both screws (A, Fig. GPC409) supplied with

the wear part kit to the brake body and tighten
8
6 5 them. This prevents the brake from falling apart,
resulting in the loss of springs and pressure items.
7
NOTE
GPC408
Now make sure that the mounting screws (1) and
WARNING spacer sleeves (5) remain in the brake body.
7. Loosen the three brake mounting screws (1) and
Oily brakes can cause accidents!
remove the brake body (2) and spacer sleeves (5)
All brake components must be kept free of oil and
from the motor (8).
grease. This includes the carrier.
8. Remove the friction plate (7) and the brake disk (6)
Installing a wear part kit and dispose of them.
Remove and disassemble the brake. Replacing wear parts
1. Switch off the truck and disconnect the battery. 9. Place the friction plate (7) in the correct position on
the bearing plate of the motor (8).
and rolling away. 10. Place the brake disk (6) on the carrier (4) on the
motor.
3. Remove the panel.
4. Remove the connector from the bushing (10, Fig.
GPC408).
5. Remove dust shield ring (9).
GPC3000
146
BRAKE SYSTEM
GPC409
15. Remove the two screws (A, Fig. GPC409).

5 16. Attach the dust shield ring (9).
GPC410 17. Restore the electrical connections.
11. Make sure the spacer bushings (5, Fig. GPC410) 18. Test the brake.
are pushed up. Pull the elastic band (B, Fig.
GPC410) provided over the 3 brake mounting
screws to secure them.
Brake re-assembly
12. Place the brake on the motor in such a way that the
connection bushing (10) for the power supply rests
back on the wire.
13. Insert the mounting screws (1), then cut through
the elastic band and dispose of it.
14. Torque the mounting screws (1) to 10 Nm.
WARNING
Possible brake failure. Remove the two transport se-
curing screws, otherwise the brakes will not work!
GPC3000
147
BRAKE SYSTEM
Replacing the brake in full 1. Place the brake on a work surface so that the elas-
tic band is facing up.
1
2
3 5
4
10 1
1 B
8
6 5
7 5
GPC408
GPC410
Removal 2. Remove the elastic band (B, Fig. GPC410) and put
1. Switch off the truck and disconnect the battery. it to one side. Do not throw it away!
and rolling away. 1
3. Remove the panel. 2
4. Remove the connector from the brake. 3
4
5. Remove the dust shield ring (9, Fig.GPC408).
6. Remove the retaining ring (3). 10 1
7. Remove the three brake mounting screws (1). 1
8. Remove and dispose of the magnetic body (2),
carrier (4), brake disk (6), spacer sleeves (5) and
friction plate (7).
9
Assembly
NOTE
8
Do not remove the elastic band or the screws. The 6 5
brake will fall apart without this transport safety mech-
anism! 7
The brake is supplied pre-assembled. Two screws and GPC408
one elastic band serve as a transport safety mecha- 3. Remove the friction plate (7), taking care not to
nism and assembly aid. lose the spacer sleeves (5).
GPC3000
148
BRAKE SYSTEM
4. Remove the carrier (4) and push it onto the drive

shaft of the motor (8).
5. Secure the carrier (4) onto the drive shaft with the
retaining ring (3).
6. Place the friction plate (7) in the correct position on
the bearing plate of the motor.
7. Take out the brake disk (6) and remove the paper.
8. Place the brake disk (6) on the carrier (4) on the
motor.
A
GPC409
13. Remove the two screws (A, GPC409).

B 14. Attach the dust shield ring (9).
15. Restore the electrical connections.
16. Test the brake.
GPC410
9. Make sure the spacer bushings (5, Fig. GPC410)

are pushed up. Pull the elastic band (B, Fig.
GPC410) provided over the three brake mounting
screws to secure them.
10. Position the brake so that it is correctly aligned with
the motor (8). The connection bushing (10) for the
power supply must rest against the wire again.
11. Insert the mounting screws (1), then cut through
the elastic band and dispose of it.
12. Torque the mounting screws (1) to 10 Nm.
DANGER
Possible brake failure. Remove the two transport se-
curing screws, otherwise the brakes will not work!
GPC3000
149
Notes:
150
STEERING
151
Notes:
152
STEERING
Steering Assembly
Steering Assembly
Intermediate flange
GPC058
GPC3000
153
STEERING
Steering Assembly
Steering Assembly Components

The steering assembly consists of the following:
• Steer motor (see page 134)
• Steering transmission and intermediate flange
Steering Assembly Removal

1. Switch off the truck, disconnect the battery and
prevent the truck from being switched on again.
2. Remove the drive motor (see page 132).
3. Undo all connections from the steer motor (see
page 134).
4. Remove the steer sensor.
5. Remove the screws (7, Fig. GPC058).
6. Lift out the steering assembly and place it on a
workbench with the steer motor facing up.
Steering Assembly Installation

Assembly is the reverse of disassembly.
Final tasks:
1. Lubricate steering toothing with type B lubricant
page 20).
GPC3000
154
STEERING
Repairing the Steering Transmission
Repairing the Steering Transmis- NOTE

sion If you are using a new intermediate flange, the cylinder
pins (13) must be removed and preserved.
See Fig. GPC058, page 153)
Drive and output disassembly:
10. Remove the retaining ring (8).
CAUTION
11. Pull the pinion shaft with the gear wheel (3), pinion
Transmission repair requires special expertise, experi- (5) and bearing (1) out of the intermediate flange.
ence and tools such as presses, extractors, measuring
equipment and assembly aids. 12. Pull the bearing (1), supporting ring (2), gear wheel
If you cannot meet these particular requirements, use (3) and key (4) off the pinion (5).
a new drive transmission unit. 13. Extract the gear wheel (9).
NOTE 14. Remove the supporting ring (10).

15. Press the output shaft (17) and the bearing (15) out
Replace all bearings and seals when repairing. of the intermediate flange.
Output shaft disassembly:
Preparation
16. Remove the key (16).
1. Remove the steering assembly (see page 154)
17. Remove the bearing (15) from the output shaft
2. Remove the steer motor (see page 134). (17).
18. Press the bearing (11) out of the intermediate
Dismantling flange.
Disassemble the end cap. 19. Remove the retaining ring (12).
3. Remove the screws (23) and take off the clamping 20. Pull the bearing (6) out of the intermediate flange.
joint (22). 21. Press the shaft seal ring (14) out of the intermedi-
4. Lift off the end cap (21). ate flange.
WARNING
Assembly
To pre-assemble the output shaft:
Health risk
Observe the manufacturer’s safety instructions when 1. Press the bearing (15) onto the output shaft (17).
handling solvents and lubricants.
2. Assemble the key (16).
5. Pour oil out of the steering transmission and dis-
To pre-assemble the pinion shaft and the interme-
pose of it in accordance with environmental regu-
diate flange:
lations.
3. Insert the key (4) into the pinion shaft (5).
6. Remove the O ring (26) from the sensor bearing
(27). 4. Press on the gear wheel (3).
7. Take the shim (25) and ring (24) out of the end cap 5. Inser the washer (2).
(21).
6. Press on the bearing (1).
8. Press the shaft seal ring (19) out of the end cap
7. Lubricate the sealing lip of the shaft seal ring (14).
(21).
8. Press the shaft seal ring (14) into the intermediate
9. Remove the seal (20).
flange.
9. Fit the retaining ring (12) in the intermediate flange.
10. Press in the bearings (6) and (11).
GPC3000
155
STEERING
Repairing the Steering Transmission
Output shaft assembly:

11. Press in the pre-assembled output shaft while sup-
porting the inner ring of the bearing (11).
12. Place the washer (10) on the output shaft (17).
13. Press the gear wheel (9) onto the output shaft (17)
while supporting the output shaft.
Pinion shaft assembly:
15. Press the pre-assembled pinion shaft into the
bearing (6).
NOTE
If you are using a new intermediate flange, tap the pre-
viously removed cylinder pins (13) into the intermedi-
ate flange.
16. Lubricate the sealing lip of the shaft seal ring (19).
17. Press the shaft seal ring (19) into the end cap (21).
NOTE
Make sure to use the correct oil grade: cold store trucks
require a different type of oil than standard trucks.
18. Add a suitable gear oil (see Recommended Lubri-
cants and Accessories, page 20).
– Capacity: approx. 0.25 litres
19. Place the seal (20) onto the intermediate flange.
20. Position the end cap (21) onto the intermediate
flange and attach it with the screws (23). Do not
forget the clamping joint (22).
21. Torque the screws (23) to 10 Nm.
22. Fit the ring (24) and spacer (25) in the end cap
(21).
Final tasks:
1. Assemble the steer motor (see page 134).
2. Install the steering assembly (see page 154)
3. Lubricate steering toothing with type B lubricant
page 20).
4. Assemble the steering sensor.
GPC3000
156
LIFTING MECHANISM
157
Notes:
158
LIFTING MECHANISM
GPC 3020/40/60 Fork Height
GPC 3020/40/60 Fork Height Adjusting the Height of the Lowered

Forks
General 1. Fully raise the forks.
The height of the lowered forks can be adjusted within 2. Switch off the truck. Disconnect the battery and
limits. The lift height is physically restricted to prevent the truck from being switched on again.
approx. 150 mm by a stop in the lift cylinder. A limit
switch (2, Fig. GPC477) cuts out the pump before the
mechanical stop in the cylinder is reached. WARNING
Risk of serious injury!

Avoid accidents by:
• Switching the truck off.
1 1
GPC477
1 Lowering stop
2 Lift cutout limit switch
3. Remove the lifting mechanism cover.

4. Pre-set the lowering stops to 33 mm (1, Fig.
GPC477).
5. Reconnect the battery.
7. Disconnect the battery and attach an anti-power up
mechanism.
GPC3000
159
LIFTING MECHANISM
GPC 3020/40/60 Fork Height
1 2 3
GPC478
1 Load wheels
2 Outrigger lever pivot points
3 Tie rod counterfix and adjusting nuts
8. Undo the tie rod counterfix nuts (1, Fig. GPC478).
90 -3 mm
90 +3 mm
GPC479
9. Adjust the fork height at the front (should be 90-3

mm measured directly above the outrigger lever
pivot point (2, Fig. GPC478)).
10. Adjust the fork height at the back on the lowering
stops (1, Fig. GPC477): It should be 90+3 mm.
11. Measure the fork height and the front and rear
again.
12. If the fork height is beyond the limit, re-adjust and
measure again.
13. Tighten the counternuts of the tie rods and the low-
ering stops.
GPC3000
160
LIFTING MECHANISM
Lift Chains
Lift Chains Cleaning Methods

Lift chains are a major component of a fork lift truck.
The chain system is designed to transmit the lift force NOTE
from the hydraulic cylinder to the forks reliably and ef-
ficiently. Safe, uninterrupted truck operation depends Never use chemical solvents or steam to clean the
on careful servicing and maintenance of the lift chains. chains. The lubricant applied at the factory will be re-
Most complaints about the chain performance are due moved from the inner plate surfaces.
to lack of maintenance. Highly stressed precision
chains require regular maintenance to ensure a long
NOTE
useful life.
Never use chemical solvents or steam to clean the
Inspection chain. The lubricant applied at the factory will be re-
moved from the inner plate surfaces.
Check the chain regularly (see “Maintenance Intervals”
table in the Lubrication & Adjustment chapter) for faults
or damage. The maintenance intervals must be re-
duced if the truck is used in a corrosive or dusty envi- WARNING
ronment. If the chain cannot be inspected on the truck,
remove it. Health risk. Observe the manufacturer’s safety in-
Check the chain regularly (see “Maintenance Intervals”
table in the Lubrication & Adjustment chapter) for faults 1. Clean the chain with paraffin, a hard bristle brush
or damage. The maintenance intervals must be re- and a lint-free cloth before inspection.
duced if the truck is used in a corrosive or dusty envi- 1. Clean the chain with paraffin, a hard bristle brush
ronment. If the chain cannot be inspected on the truck, and a lint-free cloth before inspection.
remove it.
2. Apply chain oil after the inspection (for lubricant
Main inspection items: see page 19).
• Chain wear and elongation.
Wear
• Pitting due to corrosion, in particular on the outer
surfaces of the connection plates.
WARNING
• Wear between the bolts and the connection plates.
Risk of accidents through chain wear.
• Pins turning in or extruding from the outside plates. The maximum allowed chain elongation is 3%.
If the chain has elongated by 3% replace the detacha-
• Loss of freedom of movement. ble chain anchors, anchor bolts and lift chains!
Never repair chains by cutting out the worn section and
• Damage to the anchor bolt attachment
replacing it with a new section.
• Damage to the anchor bolt attachment The chain bends as it passes over the chain rollers.
This leads to a gradual wearing of the chain links.
• Wear and corrosion to the anchor bolt and the an-
chor. Any slack a chain undergoes during its lifetime is due
to wear to the links and the chain plate eyelet.
• Wear and corrosion to the anchor bolt and anchor.
The chain wear can be measured using a wear gauge
The following sections cover the above items in detail. (Crown part no. 106440) or a steel tape measure
(siehe Abb. 2771).
GPC3000
Rev1 06/2007
161
LIFTING MECHANISM
Lift Chains
CHAIN WEAR SCALE

ROLLER AND LEAF
With taut lift chain check

either in front or rear of
pulley for elongation.
2771 7771_EU
The Crown wear gauge has two scales: If the 3% wear limit has been reached at one point,
then the chain is worn.
• Scale “A” is used for 19.05 mm (0.75 inch) and
25.4 mm (1 inch) pitch chains.
Chain pitch Number of Length Wear limit
• Scale “B” is used for 15.88 mm (0.625 inch) pitch joints (new)
chains. measured
Measurement:
25.4 mm 12 305 mm 314 mm
1. Keep the chain taut before measuring. For non-de- 1 inch 12 inch 12,375 inch
tachable lift chains the weight of the fork carriage
19.05 inch 16 305 mm 314 mm
or mast is sufficient.
0.75 inch 12 inch 12,375 inch
NOTE 15,88 mm 20 318 mm 327 mm

0.625 inch 12.5 inch 12,875 inch
The chain section that is measured must always pass
over a pulley during operation. (If a steel tape measure
is used the chain elongation test should cover at least
ten links.)
2. Take measurements from 3 different points of the
lift chain.
GPC3000
Rev1 06/2007
162
LIFTING MECHANISM
Lift Chains
Freedom of Movement of Chain Links chains have the same tension.The chain should not be
slack. If necessary, lower the forks and re-tension.
Now tighten the chain anchor counternuts again (for
DANGER torque see Lubrication & Adjustment, Torque Table).
Risk of accidents Now tighten the chain anchor counternuts again (for
torque see Lubrication & Adjustment, Torque Table).
Do not repair a damaged chain. Instead, replace it im-
mediately.
mediately.
Each individual chain link must flex freely (siehe
Abb. 2775si). Tight chain links increase friction and the
chain tension during lifting. Excessive chain tension in
turn accelerates material wear.
2775si
1. Test chain links for freedom of movement.

2. Replace any chains with stiff or rigid links immedi-
ately.
3. A chain with stiff or rigid links must be replaced im-
mediately.
Possible causes of stiff chain links are as follows:
• Bent pins or plates.
• Corroded joints.
• Peened plate edges.

Plate edge distortion is caused by:
• Ruptured chain pinion.
• Constant overloading of the chain.
• Chain striking the mast components.
Chain tension
When installed, both lift chains should have the same
chain tension to ensure even distribution of the load
over the two chains when lifting.
When replacing the forks make sure that both forks lie
evenly on the surface. If they are not even, compen-
sate the chain length via the chain anchor so that both
GPC3000
Rev1 06/2007
163
LIFTING MECHANISM
Lift Chains
Chain Anchor and Pulleys Protruding or Turned Chain Pins
DANGER DANGER
Risk of accidents Risk of accident from chain cracking!
Do not repair chain anchors or bolts. Immediately re- Do not drive back any protruding pins back into the
place damaged chain anchors and bolts with original chain. Fit new chains.
spare parts.
1. Check the chain anchor for wear. DANGER
2. Check the chain anchor fingers for cracks.
Risk of accident from chain cracking!
3. Check the pulleys for excessive wear near the Do not drive back any protruding pins back into the
flange and on the running surfaces. chain. Fit new chains.
– If signs of wear are present, check the chain
tension and mast roller setting. Replace the
pulleys if necessary.
Worn Connection Plates
DANGER
Risk of accidents
mediately.
2776S
Considerable frictional forces between the connection

plates and the pins occur when lifting heavy loads with
an insufficient or non-existent 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
2774si
chain (siehe Abb. 2776S). This can result in chain fail-
1. Check the chain for worn or missing plates (siehe ure.
Abb. 2774si).
1. Check the chain for turned and protruding pins. Not
2. Replace any chain with worn or missing plates im- all the flat ends of turned pins point in the same
mediately. direction (siehe Abb. 2776S).
2. Replace any chain with turned or protruding pins
NOTE immediately.
Chains used in pairs must always be replaced to-
gether. NOTE
1. Check the chain for worn or missing plates (siehe Chains used in pairs must always be replaced to-
Abb. 2774si). gether.
2. Replace any chain with worn or missing plates im- 1. Check the chain for turned and protruding pins. Not
mediately. all the flat ends of turned pins point in the same
direction (siehe Abb. 2776S).
2. Replace any chain with turned or protruding pins
immediately.
GPC3000
Rev1 06/2007
164
LIFTING MECHANISM
Lift Chains
Corrosion races of wear beyond a certain length on one or both

chains, on the pin heads and the outer plates are
caused by one of two factors:
• Uneven chain tension.
• Misaligned lift components.
Uneven chain tension

2773si
When fitting or adjusting the chains make sure that
they are evenly charged. If for example the fork heel
WARNING height or the platform height are changed, the chain
anchors must be loosened until both forks touch the
Replace any chains with rust marks. The risk of crack- ground.
ing as a result of rust is too great.
Replace any chains with rust marks. The risk of crack- Both chains must have equal amounts of air or tension
ing as a result of rust is too great. at this point. The lower chain anchor nuts must be tight-
ened by the same number of turns. When the required
The chains used on fork lift trucks are highly stressed height has been reached, fix the setting with the top
precision components. It is particularly important to (chain side) lock nut and its respective lock washer.
maintain the original fatigue strength throughout its
useful life. Misaligned Lift Components
Corrosion considerably reduces the capacity of a lift Misalignment of the chain pinion and the chain due to
chain. It results in cracking in the side plates. the wrong number of washers on the mast or a dam-
Lift chains must therefore be protected from corrosion. aged mast or cylinder components can also contribute
The layer of grease applied in the factory hot dip galva- to wearing of the chain sides.
nizing process is an excellent protection and fully pen- Check the alignment of the pulleys and chain anchor:
etrates the joints.
1. Position the truck on a level surface.
Do not remove this initial layer! After commissioning
the chain supplement the factory lubrication through a 2. Support the fork carriage and/or the platform.
regular lubrication schedule. 3. Remove both chains from their chain anchors and
1. Check the chain for corrosion and corrosion scars. visually inspect the alignment with the anchor
slots.
2. Remove rust film with chain oil. Replace the chain
if it already has corrosion scars. 4. Remove the chain from the chain anchor and visu-
ally inspect the alignment with the anchor slots.
1. Check the chain for corrosion and corrosion scars.
5. Determine and rectify the cause of the problem.
2. Remove rust film with chain oil. Replace both
chains even if corrosion marks are only visible on
one.
NOTE
Chains used in pairs must always be replaced to-
gether.
Side wear
Traces of wear beyond a certain length of chain, on the
pin heads and the outer plates are caused by a mis-
alignment of the lifting components.
GPC3000
Rev1 06/2007
165
LIFTING MECHANISM
Lift Chain Lubrication
Lift Chain Lubrication NOTE
A lift chain must never be allowed to dry.

General
In dusty operating conditions the multi-plate chains can
Regular lubrication has a major bearing on the chain's be more efficiently lubricated than roller chains. Multi-
useful life. plate chains consist of several plates. Therefore they
provide several paths for the lubricant to reach the
Highly stressed chains under constant use cannot last
chain bolt (siehe Abb. MS-3400-065) and allow the oil
sufficiently long if they are not regularly lubricated
to penetrate to the bearing surface on the chain bolt,
within a planned maintenance schedule.
even when the chain is dirty.
As with all contact surfaces, the tensiled steel precision
moving parts require a durable lubricant film between
the contact surfaces to avoid excessive wear. 1
Maintaining a lubricant film on all the chain surfaces
provides the following benefits:
• Restricts joint wear to a minimum (chain elonga-

tion).
• Avoids corrosion.
• Reduces the risk of chain bolts turning.
• Lessens the risk of turned chain links.
• Even chain movement and less noise as a result. MS-3400-065
• Reduced friction in the chain system. 1 Oil 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.
• Suitability to the operating temperature range, es-

pecially important for cold store trucks.
You will find details of Crown approved chain oils
in “Lubrication & Adjustment”, page 19.
Lubrication intervals depend on the operating condi-
tions 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.
A paste mixture of oil and dirt will gather on the chain
links, but they will not wear as fast as they would if they
were left to dry, leaving a metal to metal contact be-
tween the pins and plates.
GPC3000
Rev1 06/2007
166
LIFTING MECHANISM
Lift Chain Lubrication
Lubrication Intervals
See Lubrication & Adjustment, page 21.
Reduce the intervals in extreme conditions (high air hu-
midity, corrosive atmosphere, excess dust).
Lubrication
1. Clean any dirty chains before re-lubricating (siehe
Seite 161).
1. Clean any dirty chains before re-lubricating (siehe
Seite 161).
2. Apply chain oil (for lubricant see page 19).
GPC3000
Rev1 06/2007
167
LIFTING MECHANISM
Separating Lift Chains
Separating Lift Chains WARNING

Lift chains are supplied by the meter and must be cut
to the required length. Wear goggles to protect your eyes.
• Carefully grind the head of the chain bolt. The inner

Tools and Equipment Required plate surface must not be damaged.
• A secure working plate with a hole slightly larger • Place the bearing ring onto the hole in the working
than the head diameter of a chain bolt. The hole plate. The bearing ring prevents the inner plate sur-
must be deeper than the chain bolt length. face from being damaged when you drive out the
chain bolt.
• A bearing ring (washer) with a hole slightly larger
than the head diameter of a chain bolt. The bearing • Insert the head of the chain bolt to be driven out
ring thickness must be slightly larger than the into the bearing ring.
height of the head of a chain bolt.
• Press or drive out the chain bolt.
• A grinder.
• A hole with a diameter slightly shorter than the

chain bolt and a hammer. Or a press with a suitable
mandrel.
4
1
3 2
MS-3400-066
1 Connecting plate 3 Bearing ring

2 Hole in working plate 4 Grinder
GPC3000
Rev1 06/2007
168
LIFTING MECHANISM
Forks
Forks
1
General
If the forks are used to transport abrasive loads the in-
spection must be carried out at shorter intervals.
The fork tines and forks must be checked by trained
personnel at the specified maintenance intervals for
cracks, damage and wear (see Routine Maintenance,
page 21).
Repairs
DANGER MS-3400-071
Risk of fatal injury! Never carry out repair welding to

surface cracks, damaged or worn parts around the heel
of the fork.
Fork repairs must only be carried out by the manu-
facturer / qualified personnel.
Checking the Forks
DANGER
Forks showing signs of cracking, distortion or wear be-
yond the stated tolerance levels must be de-commis-
sioned. They endanger the life of the operator and
other people.
Crack Inspection
1. Inspect all fork tine surfaces for signs of cracks.
1. Inspect all fork tine surfaces for signs of cracks.
2. If necessary carry out a non-rupturing crack test
(paint penetration process or Magnaflux®).
With fork over versions, check the welding seam be-
tween the fork and the fork carriage or the fork shank
for cracks (1, Fig. MS-3400-071. Replace the forks if
any cracking is detected.
GPC3000
Rev1 06/2007
169
Notes:
170
CYLINDERS
171
Notes:
172
CYLINDERS
General
General Hydraulic System Repair

Instructions
WARNING
High pressure hydraulic system! WARNING
Escaping hydraulic oil can cause serious injury. Health risk. Observe the manufacturer’s safety in-
To avoid accidents: structions when handling solvents and lubricants.
any sections of it. • Hydraulic systems are sensitive to dirt.
• Tighten all connections before pressurising the • Thoroughly clean disassembled hydraulic compo-
system. nents before dismantling them.
• Keep hands and body away from pressurized fluid.
• Only trace leaks with a piece of paper or card-
• Always repair hydraulic components at a clean
workstation.
board.
Whenever a high pressure fluid enters the skin it must • Immediately protect cleaned and de-greased com-
be treated as a medical emergency. ponents with a thin coating of hydraulic oil.
Seek medical assistance even if the skin appears nor-
mal at first. • Protect components against re-contamination be-
fore assembling them.
Safety • Immediately seal open hydraulic ports on repaired
assemblies with dummy plugs. This also applies to
For your personal protection open ports and lines on the truck.
• Depressurise the hydraulic system before starting • Do not refinish any cylinder surfaces. Replace any
assembly work on the hydraulic system. damaged parts.
• After carrying out assembly work carefully check to • Always replace all the seals on the assembly. Used
see that all ports are tightened before re-pressuris- seals can cause leaks.
ing the system.
• Wear protective clothing, safety glasses and safety

gloves when tracing leaks or bleeding the system.
• Use a piece of absorbent paper to trace leaks,

never use your hands.
• Follow the hydraulic oil manufacturer’s safety in-

structions when handling these oils.
GPC3000 7-3400
173
CYLINDERS
Tools
Tools • Now wrap insulating tape (1, Fig. MS-3400-084)

around the shaft of the screwdriver to avoid dam-
Tools and equipment used for gaskets must be burr- aging the cylinder.
free and have no sharp edges. The tools should be
made either of soft metal (aluminium, brass) or a suita-
ble plastic. Protective mechanisms
Use small hooks to remove small seals. The same If the seal has to be pushed over sharp edges, cracks
rule applies: burr-free, rounded tips and made of soft or nicks, use appropriate protective mechanisms.
metal to avoid damaging the groove (see Fig. MS- We will now demonstrate 2 procedures – depending on
3400-083). the gasket diameter – for ensuring safe assembly.
MS-3400-083
Screwdrivers or similar tools will damage the seal seats
and the seals. This will result in leaks.
2 extractors are required to remove the gaskets
(see Fig. MS-3400-084). These must be produced
internally.
MS-3400-084
Producing extractors
• To the shaft (min. 150 mm, long, max. Ø 4 mm) of
a screwdriver hard solder a self-tapping 4 mm
screw (2, Fig. MS-3400-084).
• Sand the soldering joint.
7-3400 GPC3000
174
CYLINDERS
Gasket Assembly
Gasket Assembly
3
Old Gasket Removal
1
• Carefully turn the two tools (see Fig. MS-3400-
084) into the gasket at opposite positions.
• Pull the seal out of its seat using the grips of the
2
tools.
Large Gasket Assembly
Tools required
MS-3400-086
• Tool body
5. Push the tool body into the cylinder cap until the
– The outer diameter of the body must fit the in- gasket aligns with the groove (see Fig. MS-3400-
ternal diameter of the cylinder cap. 086).
• Three pins (1, 2 and 3). Pin (1) is fixed; pins (2) and 6. Retract the pin (3). A section of the rod seal jumps
(3) are moveable. into the seal seat (Fig. MS-3400-087).
Assembly
3
1. Apply a thin coating of hydraulic oil to the gasket
and the groove in the cylinder cap.
2. Place the gasket over the fixed pin (1) (see
Fig. MS-3400-085).
3. Bend the gasket under the pin (2).
1
2
MS-3400-087
2
MS-3400-085
4. Now bend the resultant loop up so that the pin (3)

can be moved into the loop (see Fig. MS-3400-
086).
GPC3000 7-3400
175
CYLINDERS
Gasket Assembly
7. Retract the pin (2). The gasket is now fully seated Small Gasket Assembly
in the groove.
Tools required
• Groove aligning arbor
– The outer diameter must fit the internal diame-
ter of the cylinder cap.
– The arbor should end at the bottom of the seal
seat.
• Arbor to drive in the seal.
Assembly
• Apply a thin coating of hydraulic oil to the gasket
and the groove in the cylinder cap.
MS-3400-088
8. Pull the tool body out of the cylinder cap.

• Place the cylinder cap on the groove aligning ar-
bor.
• Gently bend the gasket together.
• Place one part of the gasket into the groove.
• Push the gasket and the arbor into the groove.
MS-3400-089
7-3400 GPC3000
176
CYLINDERS
Gasket Assembly
Rod Seal Assembly, Sealing Lip First

The sealing lip is sensitive and must not be damaged.
When pushing the seal (2, Fig. MS-3400-090) over
thread and holes, special protective sleeves (1,
Fig. MS-3400-090) are required.
NOTE
The sealing lip must always face the pressure side.
MS-3400-090
GPC3000 7-3400
177
CYLINDERS
Servicing
Servicing Cylinder Disassembly
General WARNING
Carefully check the cylinder before starting repair work.
Risk of serious injury!
Check the rams for nicks, scratches and other surface Avoid accidents by:
damage. • Switching the truck off.
Check the dirt deflectors for wear and unusual leakage. • Disconnecting the battery.
If excess hydraulic oil emerges from the ram at the cyl- • Preventing the truck from being switched on again.
inder head it may be due to a damaged rod seal. Re- • Jacking up the truck and preventing it from rolling
place the rod seal and make sure that the seal seat is
away (see page 15).
clean and intact.
The cylinders are attached in different ways, depend-
Replace any parts showing signs of premature wear as
ing on the truck and their function. However, the follow-
well as parts which are already worn or damaged.
ing general rules apply for removal:
Heavily worn components must be replaced.
DANGER
WARNING
Risk of fatal injury!
Never stand underneath raised and unsecured assem-
blies.
When all the parts have been checked clean the cylin- Assemblies can accidentally lower and fatally injure
der components in a high-grade solvent and dry with you.
low-pressure pressurised air. Use suitable hard wooden blocks to prevent raised as-
semblies from lowering.
Before assembling, apply a thin layer of hydraulic oil to
the cleaned components and replacement parts. 1. Prevent the fork carriage or platform from lowering
accidentally.
When repairing the cylinder check the condition of the
guide rings. All the seal components must be always 2. Press the “Lower” switch until the rams have fully
be replaced. lowered into the lift cylinders through their own
weight.
3. Disconnect the truck's electrical system and pre-
vent it from being switched on again.
4. Jack up the truck to prevent it from starting acci-
dentally and rolling away (see page 15).
5. Using cardboard or similar material protect the
rams from being scratched where they pass
through holes.
6. Undo the hydraulic connections on the cylinders.
Collect any oil that emerges.
7. Undo the cylinder attachment.
8. Lift the cylinders out of the truck.
Replacing the Rod Seals

Check the seal groove and the ram for damage before
fitting a new seal. Otherwise, leakage will re-occur after
the new seal has been fitted.
GPC3000
178
CYLINDERS
Servicing
When replacing rod seals use assembly equipment

and tools made of soft metal or plastic without sharp
edges. Do not use a screwdriver or similar tools.
Suitable tools and assembly procedures are described
starting on page 174.
GPC3000
179
Notes:
180
PLATFORM
181
Notes:
182
PLATFORM
Platform Overview
Platform Overview
GPC045
GPC3000
183
PLATFORM
Replacing the Platform Sensors
Replacing the Platform Sensors 4. Place the mat (1) in the floorboard (5).
Platform Sensor Removal

Note: The following item numbers refer to Figure
GPC045 on page 183.
1. Remove the mat (1).
2. Undo the screws (2) and raise the floorboard (5).
3. Undo the connectors from the platform sensors
and remove the floorboard (5).
4. Mark the exact position of the platform sensors
(18) with a marking tool.
300 3
5. Undo the screws (16) and remove the platform
sensors (18) with the washers and plates (19).
Platform Sensor Assembly

1. Place the new platform sensors (18) on the 250 5
brackets and align them with the marker lines.
Note: The gap between the platform sensors (18) and TC401
switch profile (10) must be 2 - 2.5 mm.
5. Place a test weight of 10 kg with a minimum
2. Fix the platform sensors (18) with the screws (16), diameter of 100 mm on the platform as shown in
washers and plates (19). Figure TC401.
6. Via the Analyzer menu test the operation of both
Platform Assembly and Testing the platform sensors (see page 184, “Testing the
Platform Sensors via the Analyzer Menu”).
Platform Sensors
1. Insert the floorboard (5) in the truck and attach the Testing the Platform Sensors via the
platform sensor (18) connectors. Analyzer Menu
2. Fit the floorboard (5), cable bushing (4) and flange The platform sensors can be tested in the "SERVICE"
sleeves (3). menu under “ANALYZER” using the A2.3.9 FPS 1
Note: When assembling make sure that the floorboard Sensor = VALUE” and “A2.3.10 FPS 2 Sensor =
(5) is placed evenly over the four tapered nuts (17) of VALUE” sub-menus.
the U clip. To avoid platform deformation, if there is an You can navigate through the menu structures using
air gap of > 0.5 mm the clearance must be
the cursor keys ( , , , , ) on the display. An
compensated with washers (see spare parts catalog).
3. Fix the floorboard (5) with the screws (2).
GPC3000
184
PLATFORM
Replacing the Platform Sensors
overview of the menu structure can be found in Service 11. By pressing several times on the key, select the
Menu, on page 85. “A2.3.9 FPS 1 SENSOR” menu
Testing Sensors FPS 1 and FPS 2
1. Use the key to select the voltage.
– If the platform sensor is working, a reading of
approx. 2.5 volts will be displayed.
2. Press the key to select the “A2.3.9 FPS 1
SENSOR” menu.
3. Press the key to select the “A2.3.10 FPS 2
SENSOR” menu.
4. Use the key to select the voltage.
TC403 – If the platform sensor is working, a reading of
approx. 2.5 volts will be displayed.
Requirement: The test weight of 10 kg with a
minimum diameter of 100 mm must be placed on the
platform as shown in Figure TC401 (see page 184).
Possible error cause
When the platform is laden the switch profiles (10) are
1. Turn the key switch right to the "On" position.
not depressed sufficiently to activate the platform
– The display screen is activated. sensors (18). To position the switch profiles (10)
proceed as follows:
Note: On trucks without a key switch, press the key
for one second until the display screen is activated. 1. Remove the floorboard (see Platform Sensor
Removal on page 184).
2. Press the key until the “SERVICE” menu
appears. 2. Loosen the screws (11)
3. Press the key until “LEVEL 2” appears. 3. Position the switch profiles (10) in such a way that
the platform sensors (18) are activated by the test
4. Press the key until you are requested to enter weight.
your PIN.
4. Fix the switch profiles (10) with the screws (11).
5. Enter the Service PIN using the and keys and 5. Test the platform sensors (18) via the Analyzer
press . menu (see page 184).
– The service menu is now selected and the
"ANALYZER" menu is displayed.
6. Using the key select the first sub-menu.
– The “A1 STATUS” menu is selected.
7. Using the key, select “A2 INPUTS”.
8. Using the key, select “A2.1 ACCESS 1
INPUTS”.
9. Press the key until the “A2.5 ACCESS 3
INPUTS” menu appears.
10. Using the key, select “A2.3.1 TEMP ACCESS
3”.
– The “A2.3.1 TEMP ACCESS 3” menu is
displayed along with the current temperature.
GPC3000
185
Notes:
186
SCHEMATIC DIAGRAMS
187
Notes:
188
TILLER HANDLE Overview
+BV (FU1) +BV (FU1)
B5 CA 411
MAIN PCB 5
+BV (AK) +BV (AK) 6
B3 CA 410
CA 204 1
CA 205 Drive RS FS
A5 3
3
Access 1 CA 400 A4 4 POT 1
+BV (FU1) CAN-L 4
CA218 3 (Display) 9 B2 A16 1 7
_ CAN-H
86 + 30
120 Ohm
Access 3 2 8 +12V A9 5 3
K1 - BATT
Access 2 +12V 1 CA 412
CA 213 CA 200 CA 200 3 A13 7
85 - 87
CA 400
+12V
(TCM & HCM) 2 BRS
2 26 BOOTSTRAP 40 1 A1 2
U _ -K1
1 41 NCL TXD 1 4 2 4 CA 400 6
p + BV (AK) CA 206 C2 1 CA 413
Signal
4 23 PCL TXD 2 5 - BATT 2 CA 417 HNS 1
C3 8 3 1
LOAD NCL RXD 29 6 A3 10 4 2
SENSOR SMA
33 B6 9
+ OUT + OUT CA 419 HNS 2
30 SMART 7 11 5 1
STEER SENS. +BV (AK) 6 2
25 JC220-3 12 *
FPS1 Access 8 (BR)* CA 209 RAS2
L+ CA227
1 2 31 35 C A
(Interface #2) C4 2 1 CA 204 4
BRK L- CA 207 RAS3
R/T PCB
B CA228
unused 6 A2 3
(Interface #1)
2 1
A15 CA 414
*
HSS
unused
Access 8 (CAN TI)

11 - BATT PPCS1 1
FPS2 2 A1 LOS2
1 FLS 2 L+ 1 PF-dir. (FW) CA227
39 5 C A
3 A2 C7 4 3 1
L-
(RHS)
B PPCS3 LOS3 CA228
HYDR. PCB
unused 19 5 A5 A15 2
4 FF-dir. (REV) 2 3 CAN-H
unused 20 - BATT 6 A6 LOS6 3
HN HR PPCS1/3 CA237
32 B4 CA 415
unused 18 1 2 A16 4 3
RAS LOS1
HR PPCS2/4 LOS7 B1
LMS8 1 2 CA238 A6 4
FAN1 21 A14 2 3 CAN-L
1 2 28 A7 5
PPCS2 PF-dir.
unused 36 2 A3 RAS4
(FW) CA227 A14 7 1
HR BLS 1
3 A4 C6 6 5 CA 416
unused 38 2 1 * (LHS) 8 * 2
PPCS4 FF-dir. RAS5 CA228
1 ALM 2 16 - BATT 5 A7 (REV)
4 6 5 1
B BLS 6 A8 POT PCB F/C CA 416
A
A 2
LOS4 CA227
*
C BLS2 LMS9 A11
SV2 15 C8 8 7
L+
* A C Access 5
LOS5
GPC3000
L- LMS10 CA 202=B
B A13 (SCM)
8 7
W1 B6 4 STEER
- BATT BLS3 L+ A9 +12V CA 201=A
SV1 * 14 A
LMS5 SENSOR
34 C A C2 CODE +5V
C1 C B A4 High B2 1
L-
B
A
LMS6 A5 3 CA200-25 (Access 3 / Access 2)
- BATT 2
B3
Low
B4
B1
B6
B5
B2
B1
CA 208
PV 3 LMS7 LMS7.1 L+ C5 C B
L+ A7
37 C A C A
GND A10
L- L- - BATT
B B - BATT +BV (FU1) CHNL B A9
+BV (AK)
- BATT - BATT CAN-H
4 CAN-H CHNL A A8
27 * * A14
13 CAN-L +5V B5
120 Ohm
42 A6
+ +BV (AK) CAN-L CHNL B B7
LINE
CHNL B 22
- CHNL A A1 CHNL A B8
8 1 2 3 4 5 6 CA210
+12V A2 +5V B4
17 9 SAHS
CAN CONNECTION MOTOR STEERING ECR1 ECR2
TRACTION MOTOR L+ A12
ECR M1 1 W
W Signal +5V 1 +5V 1
= DC/DC 3 W
W +12V 1
A3 V M3 CHNL A 3 CHNL A 3
= V L- V
M1 CHNL A 3 2 3 CHNL B 2 CHNL B 2
V U AC
FU 2 FU 1 + Batt U 3 CHNL B 2 -B U GND 4 GND 4
1 2 P.S.
°
10 A 10 A U GND 4 -
AC + _
FU 3 + _ TS M3 B3 1 2
10 A 2 T
T TS M1 +B TS M3
1 FU 8
Note:
TS M1 12 + + A13 GND ECR1 - 32-pulse
30 A A11
LINE BD:1 BD:2 ECR2 - 48-pulse
-B GND 10
-
24V BATT -
-P
+ BF PUMP MOTOR
FU 7 + + -
+ + M2
400A
* Not available on the 3020 or 3040 without platform

Overview
SCHEMATIC DIAGRAMS
822350_2A_1
189
190
TILLER HANDLE
+BV (FU1) KYS +BV (FU1)
B5 CA 411
MAIN PCB 5
+BV (AK) +BV (AK) 6
B3 CA 410
CA 204 1
CA 205 Drive RS FS
+ BV (AK) A5 3
3
2 3 CA 400 CA 400 A4 4 POT 1
KEYPAD CAN-L 4
CA218 9 B2 A16 1 7
Access 3 _ CAN-H
120 Ohm
2 * Access 1 8 +12V A9 5 3
- BATT
Access 2 +12V 1 CA 412
CA 213 CA 200 CA 200
With Key Switch and Keypad
(TCM & HCM) 3 (Display) A13 7

+12V 2 BRS
2 26 BOOTSTRAP 40 1 A1 2
U _
1 41 NCL TXD 1 4 CA 400 4 6
p CA 206 C2 1 CA 413
Signal
4 23 PCL TXD 2 5 - BATT 2 CA 417 HNS 1
C3 8 3 1
LOAD NCL RXD 29 6 A3 10 4 2
SENSOR
33 B6 9
+ OUT + OUT CA 419 HNS 2
30 SMART 7 11 5 1
STEER SENS. +BV (AK) 6 2
25 JC220-3 12 *
FPS1 Access 8 (BR)* CA 209 RAS2
L+ CA227
1 2 31 35 C A
(Interface #2) C4 2 1 CA 204 4
BRK L- CA 207 RAS3
R/T PCB
B CA228
unused 6 A2 3
(Interface #1)
2 1
A15 CA 414
*
HSS
unused 11 - BATT PPCS1 1
Access 8 (CAN TI)

FPS2 2 A1 LOS2
1 FLS 2 L+ 1 PF-dir. (FW) CA227
39 5 C A
3 A2 C7 4 3 1
L-
(RHS)
With Key Switch and Keypad
B PPCS3 LOS3 CA228

HYDR. PCB
unused 19 5 A5 A15 2
4 FF-dir. (REV) 2 3 CAN-H
unused 20 - BATT 6 A6 LOS6 3
HN HR PPCS1/3 CA237
32 B4 CA 415
unused 18 1 2 A16 4 3
SCHEMATIC DIAGRAMS
RAS LOS1
HR PPCS2/4 LOS7 B1
LMS8 1 2 CA238 A6 4
FAN1 21 A14 2 3 CAN-L
1 2 28 A7 5
PPCS2 PF-dir.
unused 36 2 A3 RAS4
(FW) CA227 A14 7 1
HR BLS 1
3 A4 C6 6 5 CA 416
unused 2 1 (LHS)
38 * RAS5
8 * 2
PPCS4 FF-dir. CA228
1 ALM 2 16 - BATT 5 A7 (REV)
4 6 5 1
B BLS 6 A8 POT PCB F/C CA 416
A
A 2
LOS4 CA227
*
C BLS2 LMS9 A11
SV2 15 C8 8 7
* L+
A C LOS5 Access 5
L- LMS10 CA 202=B
B A13 (SCM)
8 7
CA 201=A W1 B6 4 STEER
- BATT BLS3 L+ A9 +12V
SV1 14 A
LMS5 SENSOR
GPC3000
* 34 C A C2 CODE +5V
C1 C B A4 High B2 1
L-
B
A
LMS6 A5 3 CA200-25 (Access 3 / Access 2)
- BATT 2
B3
Low
B4
B1
B6
B5
B2
L+ B1
CA 208
PV 3 LMS7 LMS7.1 C5 C B
L+ A7
37 C A C A
GND A10
L- L- - BATT
B B - BATT +BV (FU1) CHNL B A9
+BV (AK)
- BATT - BATT CAN-H
4 CAN-H CHNL A A8
27 * * A14
13 CAN-L +5V B5
120 Ohm
42 A6
+ +BV (AK) CAN-L CHNL B B7
LINE CHNL B 22
- CHNL A A1 CHNL A B8
8 1 2 3 4 5 6 CA210
+12V A2 +5V B4
17 9 SAHS
CAN CONNECTION MOTOR STEERING ECR1 ECR2
TRACTION MOTOR L+ A12
ECR M1 1 W
W Signal +5V 1 +5V 1
= DC/DC 3 W
W +12V 1
A3 V M3 CHNL A 3 CHNL A 3
= V L- V
M1 CHNL A 3 2 3 CHNL B 2 CHNL B 2
V U AC
FU 2 FU 1 + Batt U 3 CHNL B 2 -B U GND 4 GND 4
1 2 P.S.
°
10 A 10 A U GND 4 -
AC + _
FU 3 + _ TS M3 B3 1 2
10 A 2 T
T TS M1 +B TS M3
1 FU 8
Note:
TS M1 12 + + A13 GND ECR1 - 32-pulse
30 A A11
LINE BD:1 BD:2 ECR2 - 48-pulse
-B GND 10
-
+
24V BATT -
-P
+ BF PUMP MOTOR
FU 7 + + -
+ + M2
400A
* Not available on the 3020 or 3040 without platform
822350_2A_2
SCHEMATIC DIAGRAMS
TCM - Combi AC1 Power Side
TCM - Combi AC1 Power Side
INTERFACE #2 PC208-5 205

PC402-6 204
JC405-5 202 Access 3
FU1 Access 2
200 201
10A (TCM / HCM)
FU3
206 207 PC220-1 P.S.
10A
FU2 2914 PC200-4
LINE 2913
10A 2915 PVL
SCM +BF
U +
+ U
BD:1 FU8 V FU7
30A V M3 400A
W
+ B+ W +
+
- -B
24V
BATTERY
+
U
U
V
BD:2 M2 M1 V
W
W
-
-P
- -B
502 PC405-1
501 PC214-2
500
INTERFACE #2 PC208-2 503 504 PC435-B FPS1
FPS2 PC436-B 505 506 PC211-B LMS7
LMS7.1 PC212-B 507 508 PC220-2 P.S.
822350_2A_3
GPC3000
191
SCHEMATIC DIAGRAMS
TCM - Combi AC1 Logic Side
TCM - Combi AC1 Logic Side
PC201-7 2906
UNUSED 6 PC201-5 2910
13 2901 2905
2902 PC402-5
17 5900 LINE 2900
+ Batt 2904 PC214-1
+ IN
SMART 7 2912 CA201-4 EPS ACO 2907 PC208-3
°
2908
+ OUT
35 2925 PC435-C FPS1 901 PC210-1
902 PC201-14
27 900
903 PC208-4
5 2926 PC436-C FPS2 904 JC405-3
UNUSED 11 909 PC210-2
910 PC201-6
42 908
911 PC208-1 2908
37 2929 PC211-C LMS7 912 JC405-4 2903 PC435-A
2922 PC436-A
30 203
BRK 2911 PC212-A
31 5907 2909
LMS8
21 2927
33 2930 PC405-2 DISPLAY
4 2914 FU2 OUT
25 102 PC402-4 STEER SENSOR
UNUSED 18
2915
3 5901 PV
2916 * Not available on the 3020 or
UNUSED 19
* 2916 3040 without platform lift
14 5902 SV1
2917
UNUSED 20
* 2917
15 5903 SV2
2918
UNUSED 36
16 5908 2 ALM 1 2932 2920
CA223 CA223
FAN
28 5905 2 1 2924 HN
CA219 CA219
FLS
39 5904 2 1 2919
CA222 CA222
32 5906
UNUSED 24 CA213
SIGNAL 23 105 4 LOAD
U
TRANSDUCER
- 41 606 607 1
p
+ 26 301 302 2
34 2928 PC405-6 BLS 608 CONSOLE

TCM / HCM 303
2
3 JC218
NCL TXD 1 007 4
PCL TXD 2 006 5
NCL RXD 29 005 6
40 008 1
CA221
+12V 9 300 1 RED +12V ECR M1
CHNL B 22 001 2 BLU CHNL B
CHNL A 8 000 3 WHT CHNL A
UNUSED 38 600 4 BLK GND
GND 10 601 609 2 WHT TS M1
TS M1 12 103 1 BLK T
CA229
822350_2A_4
GPC3000
192
SCHEMATIC DIAGRAMS
SCM - EPS AC0 Logic Side
SCM - EPS AC0 Logic Side
CA201 CA214
SCM 1 004 3 BLU SIGNAL
SAHS
2 501 -B TCM / HCM 2 RED GND
3 2904 1 BLK +BV(AK)
4 2912 PC200-7 COMBI AC1

2900 LINE CONTACTOR
5 2910 2905 2902
2901 PC200-13
7 2906 2907 PC208-3
2908
6 910 CAN LOW CA216
ECR2 M3
GND 10 610 4 BLK GND
12 UNUSED 1 RED +12V
14 902 CAN HIGH

CA242
TS M3 13 602 2 WHT TS M3
GND 11 603 1 BLK

T
CA202
TS M3 3 104 CA241
+5V 5 703 4 BLK GND ECR1 M3
+5V 4 700 1 RED +12V

CA402 CA220
1 604 2 BRN1 2 WHT GND STEER
SENSOR
2 702 1 WHT1 1 BRN +
6 101 3 GRN1 4 YEL CCW
PC200-25 102 4 YEL1 3 GRN CW
2902 5 GRAY1 2972 K1 Pin 87

2973 JC404-3
204 6 PINK1 274 JC408-1
275 JC404-5
201 FU1 OUT
202 JC405-5
205 PC208-5
822350_2A_5
GPC3000
193
SCHEMATIC DIAGRAMS
Interface #1 Tiller
Interface #1 Tiller
INTERFACE #1 CA204
1 2982 PC410-2 BRS
2 2985 PC414-3 HSS
3 2983 PC410-10 HNS
4 2981 PC410-4 RS
5 2980 PC410-3 FS
6 2988 PC415-4 RAS
7 2989 PC415-5 LOS1
8 UNUSED
PINK1 JC402-6
9 380 PC410-5 POT HIGH
274 JC408-1
10 UNUSED
GRN2 PC405-3
11 UNUSED
931 PC400-8
12 UNUSED
GRAY1 JC402-5
13 180 PC410-7 POT WIPER 2972 K1 Pin 87
14 UNUSED WHT2 PC405-1

533 JC408-2
15 2987 PC415-2 +BV(AK)
532 PC400-4
16 580 PC410-1 GND
YEL2 PC405-4
CA205 CA404 941 PC400-9
1 WHT 1 942
2 YEL 2 531
3 PINK 3 2973
4 BRN 4 932
5 GRN 5 275
6 GRAY 6 BRN2 JC405-2
CA206
1 UNUSED
2 UNUSED
3 680 PC410-8 POT LOW
4 UNUSED
5 UNUSED
6 UNUSED
7 UNUSED
8 UNUSED
822350_2A_6
GPC3000
194
SCHEMATIC DIAGRAMS
Interface #2 Backrest
PC242
INTERFACE #2 * CA207 291 1
2 PPCS1
1 2990 3
293 4
2 2991 5 PPCS3
6
3 2994
4 2995
5 2992 PC241
292 1
6 2993 2 PPCS2
3
7 2996 294 4
5 PPCS4
8 2997 6
9 190
10 UNUSED
11 Heater PPCS
JC230 PC230 HR LHS
12 UNUSED
295 1 1 RED
590 2 2 BLU
13
JC231 PC231 HR RHS
14 297 296 1 1 RED
591 2 2 BLU
290
15
292 293 PC450-A
294 PC250-A
16 592
GRAY
295 JC226-1
CA208 296 PC437-A
297 PC438-A
1 911 PC201-6 SCM
500 -B TCM/HCM
2 503 504 PC435-B
505 PC436-B
3 2907 506 PC211-B
507 PC212-B
4 903 PC201-14 SCM 508 PC220-2
5 205 201 FU1 OUT 2900 Line Coil

2901 PC200-13
202 JC405-5
6 UNUSED 2902 PC402-5
204 PC402-6 2904 PC214-1
CA209 2905
2908
1 2942 PC450-C LMS5
2 190
3 UNUSED = platform and fork lift option

4 YEL JC226-2
5 2943 PC250-C LMS6 * Not available on the 3020
6 BLU JC226-4
2939 JC226-3
7 PINK 2940 PC437-C
2941 PC438-C
8 RED JC226-5
822350_2A_7
GPC3000
195
SCHEMATIC DIAGRAMS
INTERFACE #
PC242
INTERFACE #2 * CA207 291 1
2 PPCS1
1 2990 3
293 4
2 2991 5 PPCS3
6
3 2994
4 2995
PC241
5 2992
292 1
6 2993 2 PPCS2
3
7 2996 294 4
5 PPCS4
8 2997 6
9 190
10 UNUSED
290
LMS9
11 2968
2966
12 UNUSED
LMS10
13 2969
2967
14 UNUSED 2965
15 296 295 291 PC244-1

292 PC243-1
16 UNUSED 293 PC244-3
294 PC244-3
CA208
1 911 PC201-6 SCM
500 -B TCM/HCM
2 503 504 PC435-B
505 PC436-B
3 2907 506 PC211-B
507 PC212-B
4 903 PC201-14 SCM 508 PC220-2
5 205 201 FU1 OUT 2900 Line Coil

2901 PC200-13
202 JC405-5
6 UNUSED 2902 PC402-5
204 PC402-6 2904 PC214-1
CA209 2905
2908
1 UNUSED
2 190
3 UNUSED
4 UNUSED
5 UNUSED
= Scissor lift option
2990 PC244-2
6 2995
2994 PC243-2
* Not available on the 3020
7 UNUSED
2991 PC244-4
8 2993
2992 PC243-4
822350_2A_8
GPC3000
196
SCHEMATIC DIAGRAMS
GPC3045, 3055 Connections
GPC3045, 3055 Connections
PC435 JC435.1
MAN LIFT
* MAN LIFT *
2903 A A 2936 BRN 2935 PC435-A
504 B B 662 664 PC435-B
1 2 3 4 5 6 PC226
PC200-35 2925 C C BLK BLK PC435-C
PC436 JC436.1
2998
2976
2978
2922 A A 2934 2937 PC436-A
505 B B 665 GRN 663 PC436-B
PC200-5 2926 C C WHT WHT PC436-C
661 PC250-B
660 PC450-B
2943 PC209-5 2943 PC250-C
2942 PC209-1 2942 PC450-C
292 PC207-15 294 PC250-A
293 PC450-A
2999
2977
2933
2979
2934
2948
2935
2949
GRAY
JC437 PC437
BLK A A 296
1 2 3 4 PC227 1 2 3 4 PC228
LOS6 RED B B
WHT C C 2940 PINK PC209-7
JC438 PC438
YEL PC209-4
BLK A A 297
LOS7 RED B B BLU PC209-6
LOS2
LOS3
RAS2
RAS3
2939
WHT 2941
295
C C
RED PC209-8
1 6 3 2 4 5 JC226
822350_2A_9_1-1 822350_2A_9_1-3
SCISSORS LIFT * COMBI LIFT *

1 2 3 4 5 6 PC226
BUTT
CONNECTOR
2998
2976
2978
2959
2962
296 PC207-15
295
2995 PC209-6
2993 PC209-8
2999
2977
2933
2979
2955
2960
2956
2963
2934
2948
2935
2949
2957
2961
2958
2964
PC244
291 1 RAS5 1 2 3 4 5 6 7 8 PC227 1 2 3 4 5 6 7 8 PC228
2990 2
293 3
2991 4 LOS5
LOS2
LOS3
RAS2
RAS3
PC243
LOS4
LOS5
RAS4
RAS5
292 1 RAS4
2994 2
294 3
2992 4 LOS4
822350_2A_9_1-2 822350_2A_9_1-4
GPC3000
197
SCHEMATIC DIAGRAMS
Switch Connection
Switch Connection
CA435
2903 A BRN FPS1
504 B BLU
2925 PC200-35 C BLK
500 TCM / HCM -B
503 PC208-2 CA436
2922 A BRN FPS2
505 B BLU
2926 PC200-5 C BLK
CA211
2933 A BRN LMS7 *
506 B BLU
2929 PC200-37 C BLK
2908
2909 LMS8 CA212
2911 A BRN LMS7.1 *
507 B BLU
2933 C BLK
P.S.
CA239 CA240
DC/DC
207 FU3 OUT 1 GRN 1 RED +Uin
508 2 YEL 2 BLU -Uin
BLK +Uout
BRN -Uout
822350_2A_10
GPC3000
198
SCHEMATIC DIAGRAMS
Switch Connection
CA450
293 A BRN LMS5 *
660 B BLU
2942 PC209-1 C BLK
CA250
294 A BRN LMS6 *
661 B BLU
2943 PC209-5 C BLK
662 JC435.1-B
665 JC436.1-B 663 PC436-B
GRN GRN 664 PC435-B
292 PC207-15 295 JC226-1
GRAY GRAY 296 PC437-A
297 PC438-A
CA405
502 BATT NEG 1 WHT2
2930 PC200-33 2 BRN2 JC404-6
904 PC208-4 3 GRN2
912 PC208-1 4 YEL2
202 5 GRAY2 Adapter / K1 Pin 86
2928 PC200-34 6 PINK2 PC401-C

204 PC402-6
941 PC400-9
201 FU1 OUT 942 JC404-1
205 PC208-5 931 PC400-8
932 JC404-4
531 JC404-2
* Not available on the 3020 532 PC400-4
533 JC408-2
534 KEYPAD
822350_2A_11
GPC3000
199
SCHEMATIC DIAGRAMS
Handle Circuit
Handle Circuit
CA 411
CA 410 1
POT
2
580 PC204-16 GND 1
3
2982 PC204-1 SAS IN 2 4 POT
FS
2980 PC204-5 FORWARD IN 3 5
6
RS
2981 PC204-4 REVERSE IN 4
7
380 PC204-9 POT HIGH 5
CA 412
BLK
590 PC415-8 GND F/C 6 3
GRAY
180 PC204-13 POT WIPER 7
1 BRS
BLU BRS
2
680 PC206-3 POT LOW 8
CA 413
2984 PC415-1 +BV(AK) 9 1
CA 417
2
2 HNS1
2983 PC204-3 HORN 10 1
3 2904 HNS
2991 +BV(AK) F/C 11
*
15 x //R 4 2903
CA 419
591 PC414-4 GND F/C 12 5 2902 2
HNS2
6 2901 1
MAIN PCB F/C HNS
CA 415
2984 PC410-9 +BV/AK) 1
2987 PC204-15 +BV(AK) 2 * Not available on the 3020

2986 PC414-1 +BV(AK) 3
2988 PC204-6 4
RAS LOS1
2989 PC204-7 5
NOT USED 6 CA 416

2991 PC410-11 +BV (AK)
7 1
RED *
2990 PC204-14 +BV (AK) * 15 x //R
16 x //R
BLK
590 PC410-6 GND F/C 8 2
HYDRAULIC PCB F/C

POT PCB F/C
CA 414
2986 PC415-3 +BV(AK) 1
UNUSED 2
HSS
2985 PC204-2 3
591 PC410-12 GND F/C 4

*
2 x //R
R/T PCB F/C
822350_2A_12
GPC3000
200
SCHEMATIC DIAGRAMS
Display with Options
CA400
DISPLAY 1 UNUSED
2 631
3 2979
WHT2 JC405-1
4 532
531 JC404-2
5 UNUSED 533
534
6 UNUSED
7 UNUSED
GRN2 JC405-3
8 931 932 JC404-4
120 Ohm
9 941 YEL2 JC405-4

942 JC404-1
10 UNUSED
11 UNUSED
12 UNUSED
13 UNUSED
14 UNUSED
KEYLESS ENTRY
K1 30 30
231
2979
85 85 631
86
231
86 JC405-5 GRAY2 JC404-3 2973
87 87 2972 JC402-5 GRAY1
87a 87a 2977
BLS
KEYSWITCH CA401
ADAPTER
B
30
2982
85
2981 87
A 2977
2983
KYS 87a
86
C PINK2 JC405-6
232 232
KEYPAD HR BLS CA408 PINK1 JC402-6
KEYPAD ADAPTER 1 274 275 JC404-5
*
30
RED/WHT 2982 2 533
85
2981 87
BLK 2983
87a * Not available on the 3020
86
RED 232 232
GRN 534
822350_2A_13
GPC3000
201
SCHEMATIC DIAGRAMS
CA400
DISPLAY 1 UNUSED
2 631
3 2979
WHT2
4 532
531 JC404-2
5 UNUSED 533
534
6 UNUSED
7 UNUSED
GRN2 JC405-3
8 931 932 JC404-4
120 Ohm
9 941 YEL2 JC405-4

942 JC404-1
10 UNUSED
11 UNUSED
12 UNUSED
13 UNUSED
14 UNUSED
KEYLESS ENTRY
K1 30 30
231
2979
85 85 631
86
231
86 JC405-5 GRAY2 JC404-3 2973
87 87 2972 JC402-5 GRAY1
87a 87a 2977
BLS
KEYSWITCH CA401
ADAPTER
B
30
2982
85
2981 87
A 2977
2983
KYS 87a
86
C PINK2
232 232
KEYPAD HR BLS CA408 PINK1 JC402-6
KEYPAD ADAPTER 1 274 275 JC404-5
30
*
RED/WHT 2982 2 533
85
2981
BLK 2983 87 534
87a
BLS2 CA441
86
RED 232 232 BLU A
GRN BRN B CA440
BLK C 2971 1
2972
571 3
BLS3 CA442
2973 2 2970 JC405-6
BLU A
* Not available on the 3020 BRN B
572 4 570 JC405-1
BLK C
822350_2A_14
GPC3000
202
SCHEMATIC DIAGRAMS
CAN Connection
CAN Connection
TCM / HCM CAN LOW

CA210
COMBI AC1 42 900 901 1 CAN CONNECTION
909 2
CA200
3
4
27 908 5
CAN HIGH 6
SCM 14
902
EPS AC0 903
120 Ohm
CA201
910
6
911
* INTERFACE #2 4
903
904
CA405
CA208
1
2
911 904 3 GRN2
1
912 912 4 YEL2
5
6
CA404
INTERFACE #1 1 WHT 1 942
2
CA205
3
4 932
5
4 BRN 6
DISPLAY 9 941
120 Ohm
CA400
8 931
822350_2A_15
GPC3000
203
SCHEMATIC DIAGRAMS
Power Cables GPC 3000
Power Cables GPC 3000
24 V Battery
+ -
BATT Disconnect
821634-017 DIN160
821634-035 SBE160*(3)
821634-059 SB175*(3)
BD - 1 BD - 2
821634-016 DIN160
821634-019 SBE160*(3)
821634-058 SB175*(3) M3
U W
LINE Busbar V
818786
821630-010
821630-011
821630-012
821634-018
U V W
FU8 / 30A
M2 - EPS ACO Batt -

+
821633-037*(1) 821633-066*(1)
821633-067*(2) 821633-065*(2)
Batt +
M1
U W
V
821633-019
821633-023
821633-041
Busbar
U V W -P 818816
FU7 / 400A
COMBI AC1
Batt + Batt -
819025_2F_1
(1) On 1.5 kW motor only

(2) Option
GPC3000
204
SCHEMATIC DIAGRAMS
Harness, Walk Beside Switch
GPC3055
PC207
2990 2 1 CAN
2991 2 2 INTERFACE #2
2994 2 3
2995 2 BACKREST
4
PC242 2992 2 5
1 291 2993 2
1 6
2990 2996
HPCS1 (PF) 2 1 2 7
1 2991 2997 2
3 8
RHS 4 1 293 190 2 9
2992
HPCS3 (FF) 5 1 10
1 2993
A 6 11
12
13
14
290 2 15
16 C
PC209
1 CAN
190 2 2 INTERFACE #2
3 BACKREST
4
2994
2995
2996
2997
5
292
294
6
1 1 1 1 1 1 7
1 2 3 4 5 6 PC241 8 B
HPCS2 (PF) A
HPCS4 (FF)
LHS
818598_2G_1
See next page for tables
GPC3000
205
SCHEMATIC DIAGRAMS
Tables for Fig. 818598_2G_1 (siehe Seite 205)

Wire Connection Wire Connection
Connector housing No. No.
2997 CA207-8 CAN --- ---

Type Housing Order Number Backr.
PC241-5 WBS 4
A PC241, PC242 792881-004
B PC209 803450-008
819279-004
C PC207 116851
819279-008
Contact pins
Item no. Order Number
1 792883
2 116858
Wire connections

No. No.
2990 CA207-1 CAN 290 SPLINE1

Backr. PC207-15
PC242-2 WBS 1
2991 CA207-2 CAN 291 SPLINE1
Backr. PC242-1 WBS1
PC242-3 WBS 1
2992 CA207-5 CAN 292 SPLINE1
Backr. PC241-1 WBS2
PC242-4 WBS 2
2993 CA207-6 CAN 293 SPLINE1
Backr. PC242-4 WBS3
PC242-5 WBS 2
2994 CA207-3 CAN 294 SPLINE1
Backr. PC241-4 WBS4
PC241-2 WBS 3
2995 CA207-4 CAN --- ---
Backr.
PC241-3 WBS 4
2996 CA207-7 CAN 190 PC207-9
Backr. PC209-2
PC241-4 WBS 4
GPC3000
206
SCHEMATIC DIAGRAMS
Beside Switch Assy
Beside Switch Assy
GPC3055 (no PPC)

JC241
BLK
BLU
BLK (WBS1/2) 1 1 (JC242)
PF HPCS1 GREY (WBS1/2) 1 2
(HPCS2) GREY BLU (WBS1/2) 1 3
BLK (WBS3/4) 1 4
BLK GREY (WBS3/4) 1 5
FF HPCS3 BLU BLU (WBS3/4) 1 6 A
(HPCS4) GREY
818950_2F_1
Connector housing
Type Housing Order Number
A JC241 (JC242) 792880-004

Anti Back Out 793090-004
Contact pins
Item no. Order Number
1 792882
GPC3000
207
SCHEMATIC DIAGRAMS
CAN Interface Bridge
GPC3055
CAN INTERFACE #2 CAN INTERFACE #2

B BACKREST A BACKREST
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PC207 1 2 3 4 5 6 7 8 PC209
1 1
190
190
150
819364_2A_1
Connector housing
A PC209 803450-008
819279-004
B PC207 116851
819279-008
Contact pins
Item No. Order Number
1 116858
GPC3000
208
SCHEMATIC DIAGRAMS
Lift / Lower Scissors Harness
Lift / Lower Scissors Harness
GPC3040 / 3060, GPC3045

PC244 291
1 1
RAS 5 2990
2 1 295
293 3 BUTT SPLICE
3 1
LOS 5 2991
A 4 1 296
PC207-15 2
2995
2 PC209-6
CAN
2993 INTERFACE #2
2 PC209-8 BACKREST
2994
2992
292
294
1 1 1 1
1 2 3 4 PC243
A
LOS 4
RAS 4
819554_2E_1
Connector housing
A PC243, PC244 792881-003
Contact pins
1 792883
2 116858
3 816812-072
GPC3000
209
SCHEMATIC DIAGRAMS
Scissors RAS - LOS Assy
Scissors RAS - LOS Assy
GPC3055 (no PPC)

BLK
JC243 (JC244)
RAS4/5 BLU BLK RAS4/5
GREY
1 1
2 Forks
BLU RAS4/5 1
BLK LOS4/5 1
BLK 3
BLU LOS4/5 1
LOS4/5 BLU 4 A
GREY
819556_2F_1
Connector housing
A JC243 (JC244) 792880-003

GPC3000
210
SCHEMATIC DIAGRAMS
Walk Beside Switch Harness F/C
JC231
296 PC207
1 4 2990 2
4 591 1 CAN
D 2 2991 2 2 INTERFACE #2
2994 2 BACKREST
3
2995 2 4
PC242 2992 2 5
1 291 2993 2
1 6
1 2990 2996 2
WBS1 (PF) 2 7
1 2991 2997 2
3 8
RHS 4 1 293 190 2 9
1 2992
WBS3 (FF) 5 10
1 2993
A 6 11
12
13
297 3 14
290 2 15
592 2 16 C
PC209
1 CAN
190 22 INTERFACE #2
3 BACKREST
2994
2995
2996
2997
4
292
294
295
590
5
4 4 1 1 1 1 1 1 6
7
1 2 JC230 1 2 3 4 5 6 PC241 8 B
D WBS2 (PF) A
WBS4 (FF)
LHS
820541_2B_1
GPC3000
211
SCHEMATIC DIAGRAMS
Tables for Fig. 820541_2B_1 (siehe Seite 211) Wire connections
Connector housing
No. No.
2990 CA207-1 CAN 290 SPLINE1
A PC241, PC242 792881-004 Backr. PC207-15
PC242-2 WBS 1
2991 CA207-2 CAN 291 SPLINE1
B PC209 803450-008
Backr. PC242-1 WBS1
Sealing 819279-004 PC242-3 WBS 1
C PC207 116851 2992 CA207-5 CAN 292 SPLINE1
Backr. PC241-1 WBS2
Sealing 819279-008
PC242-4 WBS 2
D JC230, JC231 792880-001
2993 CA207-6 CAN 293 SPLINE1
Anti Back Out 793090-001 Backr. PC242-4 WBS3
PC242-5 WBS 2
Contact pins 2994 CA207-3 CAN 294 SPLINE1
Backr. PC241-4 WBS4
Item No. Order Number PC241-2 WBS 3
2995 CA207-4 CAN 295 PC207-14
1 792883 Backr. JC230-1
2 116858 PC241-3 WBS 4
3 803450-049 2996 CA207-7 CAN 296 PC207-14

Backr. JC231-1
4 792882 PC241-4 WBS 4
2997 CA207-8 CAN 590 PC207-16
Backr. JC230-2
PC241-5 WBS 4
190 PC207-9 591 PC207-16
PC209-2 JC231-2
GPC3000
212
SCHEMATIC DIAGRAMS
Microswitch Assy
Microswitch Assy
3 4 5
792991_2E_1
Connector housing
3 PIN Housing 792880-002

3 Way
5 Anti Back Out 793090-002
3 Way
Contact pins
4 792882
GPC3000
213
SCHEMATIC DIAGRAMS
Horn Harness
Horn Harness
PC419
2901
PC413 2 1
2901 2902
6 1 2 2
2902
5 1
2903
4 1
2904 PC417
3 1 2903
2 1
2 2904
2 2
1
811931_2E_1
Connector housing
Housing Order Number
PC413 803450-021
PC419 803450-023
PC417 803450-023
Contact pins
1 803450-022
2 803450-024
GPC3000
214
SCHEMATIC DIAGRAMS
Horn Switch Assembly
Horn Switch Assembly
JC417/419
4 2
4 1
811933_2D_1
GPC3000
215
SCHEMATIC DIAGRAMS
SAS Switch Assembly
SAS Switch Assembly
5 1 JC412
5 2
5 3
811935_2D_1
Contact pins
5 803450-022
GPC3000
216
P.S. (Opt.) ALM (Opt.) SAHS FLS (Opt.) SV1
A A E A FORKS SV2 C PS D CAN CONN.
1 2 PC239 1 2 PC223 1 2 3 PC214 1 2 PC222 PVL LIFT MAN LIFT 1 2 3 4 PC213 PC200 1 2 3 4 5 6 PC210
14+15 14+15 14+15 14+15 14+15 14+15 007 1 1
1 1 1 1 2 2 2 1 1 1 1 1 9 1 FILTER
Main Harness GPC 3000
006 2
8
901
909
5901 1 2 3 4 5
207
508
501
004
607
302
105
3
2916
2915
5901
2916
2917
5902
2917
2918
5903
8
2932
5908
2904
2919
5904
2914 4 FU1 FU2 FU3 HN
8 12+13 12+13 18 18 18
2926 12+13 12+13 12+13 12+13 12+13 12+13
8 5
6
509
201
200
207
206
2933
5906
2920
2933
2912 7
2915
2914
2913

8
000 8
8
300 9
8
601 10
PC202 8
11
604 103
3 1 8 12
702 2901 13
3 2 8
5902 14
104 9
3 3 5903
9 15 I CONN. HAND SET
700 5908
3 4 8 16
703 5900 17 1 2 3 4 5 6
3 5 8 JC218
300 18
JC221 1 6 101 5 5 5 5 5 5
3 6
EPS ACO
001 19 2900
12+13
ECR M1 2 6 003
3 7 COIL
008
608
303
007
006
005
20 5900
000 2927 12+13
3 6 002 8 21
3 8 G
600 001
K 4 6 8 22 LINE
105 2913
8 23 12+13 OUT
24 200 CONTACTS
103 PC201 102 12+13 IN
1 6 8 25 206
JC229 301 26
609 1 8
CAN TS M1 2 6 900
8 27 BATT -
2 5905 28
CONTROLLER COMBI AC1

F INTERF. BR #2 J 9 10
004 005
3 3 9 29
1 2 3 4 5 6 PC208 700 2912 203 Use Cap AMP F42
1 6 3 4 8 30
3 3 3 3 3
JC224 5907 31
003 2910 8
ECR1M3 2 6 3 5 5906
8 32
502
501
500
002 910 2930

3 6 3 6
911
503
903
205
8 33
2907
603 2906 2928 34
K 4 6 3 7 8
2925 35
010 8
3 8
36
009 2929
GPC3000
104 3 9
EPS ACO
JC225 1 6 8 37
602 610 38
2 6 3 10
TS M3 5904 39
603 8
3 11 008
J 8 40
12 606 41
8
LMS8 203 602 908 42
16+17 3 13 9 L
com n.c.
2924
5905
BRK 5907 902

11 11 16+17 3 14 H
1 1
1 2 PC219
2909
2927
703
JC216 1 6
010
A FAN
ECR2M3 2 6
009
3 6
610
K 4 6
BATTERY BATTERY
B FPS1 B FPS2 B LMS7 B LMS7.1 D COVER I COVER
A B C PC435 A B C PC436 A B C PC211 A B C PC212 1 2 3 4 5 6 PC402 1 2 3 4 5 6 JC405
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5 5 5 5 5 5
504
505
506
507
702
604
101
102
204
502
904
912
202
2903
2925
2922
2926
2931
2929
2911
2931
2902
2930
2928
818240-1_2Q
SCHEMATIC DIAGRAMS
217
SCHEMATIC DIAGRAMS
Tables for Fig. 818240-1_2Q (siehe Seite 217) Cable lugs
Connector housing
Typ Assembly Order Number Designation
e Location
10 BATT - 816812-063 Ring Terminal
A PC219, PC222, 792881-001
11 LMS8 816812-050 Ring Terminal
PC239, PC223
12 FU1, FU2, 816812-089 Positive Lock
Line Cont.,
B PC211, PC212, 792881-002 Horn
PC435, PC436
13 --- 816812-018 Insulation
Anti Back Out 793091-002 Sleeve
C PC213 792881-003 14 PVL, SV1, 816812-075 Faston
SV2 Receptacle
16 BRK 816812-096 Positive Lock
D PC210, PC402 792881-004
17 --- 816812-098 Positive Lock
18 Filter 816812-022 Ring Terminal
E PC214 062755-002
--- 813412-004 Shrinking Tube
F PC208 803450-007
Sealing 819279-003
G PC202 803450-008
Sealing 819279-004
H PC201 803450-044
Sealing 819279-007
I JC218, JC405 792880-004
J JC225, JC229 820264-001
Sealing 820268-002
K JC216, JC221, 820264-003
JC224
Sealing 820268-002
L PC200 814155
Sealing 963530-1
Sealing 963294-1
GPC3000
218
SCHEMATIC DIAGRAMS
Contact pins
No. No.
2926 PC200-5 5905 PC200-28
1 792883 Controller Controller
2 062797-004 PC436-C FPS2 PC219-2 FAN
3 116858 2927 PC200-21 5906 PC200-32

Controller Controller
5 792882 LMS8 HORN
6 820265-002 2928 PC200-34 5907 PC200-31
Wire connections JC405-6 BRK
2929 PC200-37 5908 PC200-16
Wire Connection Wire Connection Controller Controller
No. No. PC211-C LMS7 PC223-2 ALM
(option)
2900 SPLINE1 2912 PC201-4 EPS
2930 PC200-33 --- ---
LINE COIL PC200-7
Controller
Controller
JC405-2
2901 SPLINE1 2913 LINE OUT
2931 PC211-A 000 PC200-8
PC200-13 FU2 IN
PC212-C Controller
Controller
JC221-3 ECR M1
2902 SPLINE1 2914 FU2 OUT
2932 PC223-1 ALM 001 PC200-22
PC402-5 PC200-4
(option) Controller
Controller
SPLINE10 JC221-2 ECR M1
2903 SPLINE3 2915 FU2 OUT
2933 HN 002 PC202-8 EPS
PC435-5 FPS 1 PVL
FILTER Pin 3 JC224-3 ECR1 M3
2904 SPLINE1 2916 PVL
--- --- 003 PC202-7 EPS
PC214-1 SV1 (option)
JC224-2 ECR1 M3
2905 SPLINE1 2917 SV1 (option)
5900 PC200-17 004 PC201-3 EPS
SPLINE7 SV2 (option)
Controller PC214-3
2906 SPLINE7 2918 SV2 (option) LINE COIL
PC201-7 EPS SPLINE10
5901 PC200-3 005 PC200-29
2907 SPLINE1 2919 PC222-1 Controller Controller JC218-6
PC208-3 FLS (option) PVL Interface Con.
CAN Backr. SPLINE10
5902 PC200-14 006 PC200-2
2908 SPLINE1 2920 HN Controller Controller JC218-5
SPLINE3 FILTER Pin 1 SV1 (option) Interface Con.
2909 SPLINE3 2922 PC436-A FPS2 5903 PC200-15 007 PC200-1
LMS8 SPLINE3 Controller Controller JC218-4
SV2 (option) Interface Con.
2910 SPLINE7 2924 PC219-1 FAN
PC201-5 EPS SPLINE 10 5904 PC200-39 008 PC200-40
2911 SPLINE3 2925 PC200-35
PC222-2 FLS JC218-1 Interface
PC212-A Controller
(option) Con.1
LMS7.1 PC435-C FPS1
GPC3000
219
SCHEMATIC DIAGRAMS
Wire Connection Wire Connection Wire Connection Wire Connection

No. No. No. No.
009 PC216-3 300 PC200-9 600 SPLINE 11 900 SPLINE 5

ECR2 M3 Controller JC221-4 ECR PC200-27
PC201-9 EPS JC221-1 ECR M1 M1 Controller
010 PC216-2 301 PC200-26 601 SPLINE 11 901 SPLINE 5
ECR2 M3 Controller PC200-10 PC210-1
PC201-8 EPS SPLINE 8 Controller
101 PC202-6 EPS 302 PC213-2 PS 602 JC225-2 ECR1 902 SPLINE 5
PC402-3 SPLINE 8 M3 PC201-14 EPS
PC201-13
102 PC200-25 303 JC218-3
Controller SPLINE 8 603 JC224-4 ECR1 903 PC208-4 CAN
PC402-4 M3 Backr.
PC201-11 SPLINE 7
103 JC229-1 TS/M1 500 BATT NEG
PC200-12 SPLINE 12 604 PC402-2 904 SPLINE 7
Controller PC202-1 EPS JC405-3
AC0
104 JC225-1 TS M3 501 BATT NEG
PC202-3 EPS PC214-2 606 SPLINE 9 908 SPLINE 6
Straight Ah. PC200-41 PC200-42
105 PC213-4 PS 502 BATT NEG
PC200-23 JC405-1 607 SPLINE 9 909 SPLINE 6
Controller PC213-1 PS PC210-2
200 LINE 503 SPLINE 12 608 SPLINE 9 910 SPLINE 6
CONTACTS IN PC208-2 CAN JC218-2 PC201-6 EPS
FU1 IN Back.
609 SPLINE 11 911 PC208-1 CAN
201 FU1 OUT 504 SPLINE 12 JC229-2 TS M1 Backr.
SPLINE 2 PC435-B FPS1 SPLINE 7
202 JC405-5 505 SPLINE 12 610 JC216-4 ECR2 912 SPLINE 7
SPLINE 2 PC436-B FPS2 M3 JC405-4
PC201-10 EPS
203 PC200-30 506 SPLINE 12
Controller PC211-B LMS7 --- --- --- ---
BRK
700 PC202-4 EPS --- ---
204 PC402-6 507 SPLINE 12 JC224-1 ECR1
SPLINE 2 PC212-B LMS7.1 M3
205 PC208-5 508 SPLINE 12 702 PC202-2 EPS --- ---
SPLINE 2 PC239-2 Power S. PC402-1 Batt.
Cover
206 LINE 509 SPLINE 12
CONTACTS IN FILTER Pin 5 703 PC202-5 EPS --- ---
FU3 IN JC216-1 ECR2
M3
207 FU3 OUT --- ---
PC239-1
Power S.
GPC3000
220
SCHEMATIC DIAGRAMS
X10 Handle Harness
X10 Handle Harness
PC204 PC414
2982
CAN 1 1 2986
1 1 X10-
2985
INTERFACE 2 1
HANDLE
2
TILLER 3 1
2983
2985
1 3
2981
4 1
2980
582
1
4 A
5 1
2988
6 1
2989
7 1
PC415
8
380 2984
9 1
1 1 X10-
2987
10
1 2 HANDLE
2986
11
1 3
2988
12
1 4
180 2989 1
13 1 5
2990 2991 6
14 1
2987 2990
15 1
2 7
581
E 16 1
580 1 8 B
PC410
580
1 1 X10-
2982
1 2 HANDLE
2980 3
1
PC206
2981 4
1
CAN 1
380
1 5
INTERFACE 2
581
1 6
TILLER 3 1
680
180 7
1
4
680
1 8
5
2984
1 9
6
2983
1 10
7
2991
1 11
C 8
582
1 12 D
818595_2E_1
Connector housing Contact pins
Type Housing Order Number Item No. Order Number
A PC414 803450-020 1 116858

B PC415 803450-008 2 803450-049
C PC206 803450-008
D PC410 803450-009
E PC204 116851
GPC3000
221
SCHEMATIC DIAGRAMS
X10 Handle Harness
Wire connections

No. No.
2980 PC410-3 Handle 2990 PC415-7 Handle

PC204-5 CAN PC204-14 CAN
Tiller Tiller
PC204-4 CAN PC410-11 Handle
Tiller
2982 PC410-2 Handle --- ---
PC204-1 CAN
Tiller
2983 PC410-10 180 PC410-7 Handle
Handle PC204-13 CAN
PC204-3 CAN Tiller
Tiller
PC415-1 Handle PC204-9 CAN
Tiller
Tiller Tiller
PC415-3 Handle PC410-6 Handle
PC204-15 CAN PC410-12 Handle
Tiller
Tiller Tiller
2989 PC415-5 Handle --- ---
PC204-7 CAN
Tiller
GPC3000
222
F HR D BLS
1 2 JC408 A B C PC401 JC404
1 1 3 3 942
1 1
531
1 2
274
533
2977
2973
PINK 2
1 3
Display Harness GPC 3000
932
1 4
275
1 5

JC402 BRN2
WHT1 1 6 B
1 1
BRN1
2 1
GRN1
3 1
BATTERY YEL1 JC220
4 1
COVER GRAY1 WHT1
5 1 1 1
PINK1 BRN1
B 6 1 1 2
YEL1 STEER SENSOR
1 3
GRN1
1 4 A
PC405
WHT2
PC400
1 3
BRN2 1
2 3 631 DISPLAY
GRN2 2 2
3 3 2979
BATTERY YEL2 2 3
4 3 532
COVER 2 4
GPC3000
GRAY2
5 3
PINK2 5
E 6 3
6
7
931
2 8
941
2 9
10
11
12
13
14 C
534
6+7
Detail B
Detail A
2979 Adapter
231
5 30 2979 30 KYS
2977 2982
2981
2972 5 87 2977
87
631 Socket 2972 2983
4 85
GRAY2
Coil Contact
5 86 GRAY2 86 232
231 G 232
SCHEMATIC DIAGRAMS
818597_2L_1
223
SCHEMATIC DIAGRAMS
Tables for Fig. 818597_2L_1 (siehe Seite 223)

Contact pins No. No.
GRAY JC402-5 --- ---

Item No. Order Number 1 SPLINE 3
1 792882 PINK1 JC402-6 631 PC400-2

JC404-5 SOCKET-85
3 792883
WHT2 JC405-1 931 SPLINE 4
4 813444-001 SPLINE 1 PC400-8
6 816812-089 BRN2 PC405-2 932 SPLINE 4
7 816812-091 JC404-6 JC404-4
GRN2 SPLINE 4 941 SPLINE 5
Connector housing PC405-3 PC400-9
YEL2 SPLINE 5 942 SPLINE 5
Type Housing Order Number PC405-4 JC404-1
GRAY PC405-5 2972 SOCKET 87
A JC220 792880-003
2 SOCKET-86 SPLINE 3
PINK2 PC405-6 2973 PC404-3
B JC404, JC402 792880-004 PC401-C SPLINE 3
Anti Back Out 793090-004 231 SOCKET 86 2977 PC401-A
SOCKET 30 SOCKET 87
C PC400 ---
274 PC408-1 2979 SOCKET 30
D PC401 792881-002
SPLINE 2 PC400-3
275 JC404-5 --- ---
E PC405 792881-004 SPLINE 2
F JC408 792880-001
G Socket 811996-003
Wire connections

No. No.
WHT1 JC402-1 531 SPLINE 1

JC220-1 JC404-2
BRN1 JC402-2 532 SPLINE 1
JC220-2 JC400-4
GRN1 JC402-3 533 SPLINE 1
JC220-4 JC408-2
YEL1 JC402-4 534 SPLINE 1
JC220-3
GPC3000
224
SCHEMATIC DIAGRAMS
Adapter ZAPI Console
Adapter ZAPI Console
PC218 PC405
014 1
Bootstrap 1 1 011
611 2 2 NCL RXD
-12V 2 1
012
311 2 3 PCL TXD
+12V 3 1 013
TRUCK 013 2 4 NCL TXD
SIDE
NCL TXD 4 1
611 ZAPI
012 2 5 -12V
PCL TXD 5 1 311 CONSOLE
011 2 6 +12V
NCL RXD 6 1
014
2 7 Bootstrap
A
2 8 B
818624_XD_1
Contact pins
1 792883
2 ---
Connector housing
A PC218 792881-004
B PC405 ---
GPC3000
225
SCHEMATIC DIAGRAMS
BRK Switch Assembly
BRK Switch Assembly
X10 - Handle
JC 212
1
2 6
3
5
818731_2E_1
Contact pins
5 803450-022
6 803450-061
GPC3000
226
SCHEMATIC DIAGRAMS
GPC 3000 Standard
GPC 3000 Standard
CAN-Tiller Harness Assembly

WHT
PC404 1 1 WHT
2 1 JC205
YEL YEL
2 1 2 2
3 1 PINK PINK
2 3 CAN
DISPLAY 1
BRN BRN INTERFACE
4 2 4
HARNESS 5 1
GRN GRN TILLER
2 5
A 6 1 GREY GREY
2 6 B
818876_2F_1
Contact pins
1 792883
2 116858
Connector housing
A PC404 792881-004
B JC205 803450-007
Sealing 819279-003
GPC3000
227
SCHEMATIC DIAGRAMS
GPC Standard 3000
GPC Standard 3000
Steer Sensor Assembly

PC220
BRN BRN
+ 1 1
STEER CW GRN WHT DISPLAY
1 2
SENSOR CCW YEL YEL
1 3 HARNESS
GND WHT GRN
1 4 A
818949_2E_1
Contact pins
1 792883
Connector housing
A PC220 792881-003
GPC3000
228
SCHEMATIC DIAGRAMS
Walk Beside Switch Assy
Walk Beside Switch Assy
JC241
BLK
BLU
BLK (WBS1/2) 1 1 (JC242)
PF HPCS1 GREY (WBS1/2) 1 2
(HPCS2) GREY BLU (WBS1/2) 1 3
BLK (WBS3/4) 1 4
BLK GREY (WBS3/4) 1 5
FF HPCS3 BLU BLU (WBS3/4) 1 6 A
(HPCS4) GREY
818950_2F_1
Contact pins
1 792882
Connector housing
A JC224 (JC225) 792880-004

GPC3000
229
230
Platform Lift Harness
A FPS2 CAN Interface A LMS5

Backrest #2
A B C PC436 A B C PC450
1 1 1 1 1 1

663
293
660
2937
WHT
2942
PC207-15
CA209-4 Platform RAS
CA209-7 Platform LOS
CA209-1 LMS5
CA209-5 LMS6
CA209-6 Forks RAS
CA209-8 Forks LOS
3 3 3 3 3 3
292
YEL
RED
2942
2943
BLU
PINK
SCHEMATIC DIAGRAMS
GPC3000
JC226
295
2 1
YEL
2 2
2939
2 3
BLU
2 4
RED
2 5
6 C
2935
664
BLK
296
2940
297
2941
2936
662
BLK
2934
665
WHT
294
661
2943
1 1 1 1 1 1 1 2 2 2 2 2 2 1 1 1
A B C PC435 A B C PC437 A B C PC438 A B C JC435.1 A B C JC436.1 A B C PC250
A FPS1 A LOS A LOS B B A LMS6
PLATFORMLIFT PLATFORMLIFT
819029_2G_1
SCHEMATIC DIAGRAMS
Contact pins Wire connections
Item No. Order Number Wire Connection Wire Connection

No. No.
1 792883
2934 JC436.1-A BLU JC226-4
2 792882
SPLINE 8 CA209-6 RAS/
3 116858 Forks
2935 PC435-A RED JC226-5
Connector housing SPLINE 3 CA209-8 LOS/
Forks
Type Housing Order Number 2936 JC435.1-A BLK PC435-C
SPLINE 8 JC435.1-C
A PC250, PC450, 792881-002
PC435, PC436, 2937 PC436-A 292 SPLINE 2
PC437, PC438 SPLINE 3 CA207-15
B JC435.1, 792880-002 2939 JC226-3 293 SPLINE 2

JC436.1 SPLINE 7 PC450-A LMS5
C JC226 792880-004 2940 PC437-C 294 SPLINE 2

SPLINE 7 PC250-A LMS6
2941 PC438-C 295 SPLINE 6
SPLINE 7 JC226-1
2942 PC450-C LMS5 296 SPLINE 6
CA209-1 CAN PC437-A
INT. #2
2943 PC250-C 297 SPLINE 6
CA209-5 CAN PC438-A
INT. #2
GRAY SPLINE 2 660 PC450-B LMS5
SPLINE 6 SPLINE 1
WHT JC436.1-C 661 PC250-B LMS6
PC436-C SPLINE 1
BRN SPLINE 3 662 JC435.1-B
SPLINE 8 SPLINE 1
PINK CA209-7 CAN 663 SPLINE 5
INT. #2 PC436-B FPS2
SPLINE 7
YEL CA209-4 CAN 664 SPLINE 5
INT. #2 PC435-B FPS1
JC226-2
GRN SPLINE 1 665 SPLINE 1
SPLINE 5 JC436.1-B
GPC3000
231
SCHEMATIC DIAGRAMS
Backrest Harness #2 Platform Lift
Backrest Harness #2 Platform Lift
PC227
PC226 2999
2998 1 1 RAS2
1 1 2977
2976 1 2
2 1 2933 RHS
2978 1 3
3 1 2979
1 4 B LOS2
4
5
A 6
PC228
2934
1 1 RAS3
2948
1 2
2935
1 3
LHS
2949
1 4 B LOS3
819030_2E_1
Contact pins
1 792883
Connector housing
A PC226 792881-004
B PC227, PC228 792881-003
GPC3000
232
SCHEMATIC DIAGRAMS
Straight Ahead Sensor Assy
Straight Ahead Sensor Assy
SAHS JC214
+ 1 BRN
BRN 1
A
- 3 BLU BLU 1 B
BLK 1
Sig BLK C A
4
819113_2E_1
Contact pins
1 792882
Connector housing
A JC214 792880-002
GPC3000
233
SCHEMATIC DIAGRAMS
CAN INTERFACE #2 CAN INTERFACE #2

B BACKREST A BACKREST
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PC207 1 2 3 4 5 6 7 8 PC209
1 1
190
190
150
819364_2A_1
Contact pins
1 116858
Connector housing
A PC209 803450-008
Sealing 819279-004
B PC207 116851
Sealing 819279-008
GPC3000
234
SCHEMATIC DIAGRAMS
Lift Lower Scissors Harness GPC 3000
Lift Lower Scissors Harness GPC 3000
PC244 291
1 1
RAS 5 2990
2 1 295
293 3 BUTT SPLICE
3 1
LOS 5 2991
A 4 1 296
PC207-15 2
2995
2 PC209-6
CAN
2993 INTERFACE #2
2 PC209-8 BACKREST
2994
2992
292
294
1 1 1 1
1 2 3 4 PC243
A
LOS 4
RAS 4
819554_2E_1
Contact pins
1 792883
2 116858
3 816812-072
Connector housing
A PC243, PC244 792881-003
GPC3000
235
SCHEMATIC DIAGRAMS
LMS Harness Scissors Lift
LMS Harness Scissors Lift
2965 2966 2 NC
CA207-15
2968
CA207-11 1 LMS9
2969 2968 2 Low
CA207-13 1
2969
2967
2 2
Low NC
LMS10
819555_2C_1
Contact pins
1 116858
2 052062-004
GPC3000
236
SCHEMATIC DIAGRAMS
Scissors RAS - LOS Assy GPC 3000
Scissors RAS - LOS Assy GPC 3000
BLK
JC243 (JC244)
RAS4/5 BLU BLK RAS4/5
GREY
1 1
BLU RAS4/5 1 2
BLK LOS4/5 1
BLK 3
BLU LOS4/5 1
LOS4/5 BLU 4 A
GREY
819556_2F_1
Connector housing
A JC243, JC244 792880-003

GPC3000
237
SCHEMATIC DIAGRAMS
Platform Lift Fork Switch Assembly RAS / LOS 2-5
Platform Lift Fork Switch Assembly RAS / LOS 2-5
BLK
RAS2 (3) BLU

GREY
JC237
PLATFORM BLK RAS2/3
BLK
1 1
BLU RAS2/3
BLU 1 2
LOS2 (3) BLK LOS2/3 PLATFORM
GREY 1 3
BLU LOS2/3
1 4
BLK RAS4/5
1 5
BLK BLU RAS4/5
RAS4 (5) 1 6
BLU
BLK LOS4/5 FORKS
GREY 1 7
BLU LOS4/5
1 8 A
FORKS
BLK
LOS4 (5) BLU

GREY
819557_2E_1
Connector housing
A JC237 (JC238)
GPC3000
238
SCHEMATIC DIAGRAMS
Backrest Harness #2 Platform / Forks
Backrest Harness #2 Platform / Forks
PC237
2999 1 1
2977 1 2 RAS2
PC226 2933 1 3 Platform
2998
1 1 2979 LOS2
2976 1 4
2 1 2955 RHS
2978 1 5
3 1 2960 RAS4
2959 1 6
4 1 2956 Forks
2962 1 7
5 1 2963 LOS4
1 8 B
A 6
PC238
2934 1 1
2948 1 2 RAS3
2935 1 3 Platform
2949 1 4 LOS3
2957 1 5 LHS
2961 1 6 RAS5
2958 1 7 Forks
2964 1 8 B LOS5
819568_2C_1
Contact pins
1 792883
Connector housing
A PC226 792881-004
B PC237, PC238 792881-005
GPC3000
239
SCHEMATIC DIAGRAMS
Battery Latch Switch (BLS) Assy
Battery Latch Switch (BLS) Assy
JC401
BLK BLK 1
A
WHT WHT 1
B
RED RED 1 C
A
820075_2D_1
Contact pins
1 792882
Connector housing
A JC401 792880-002
GPC3000
240
SCHEMATIC DIAGRAMS
Adapter Key Switch
Adapter Key Switch
2982
2981 30
2981 2983
1+2 87
232
86
232
1+2
85
87a
820143_2D_1
Contact pins
1 816812-089
2 816812-091
GPC3000
241
SCHEMATIC DIAGRAMS
JC231
296 PC207
1 4 2990 2
4 591 1 CAN
D 2 2991 2 2 INTERFACE #2
2994 2 BACKREST
3
2995 2 4
PC242 2992 2 5
1 291 2993 2
1 6
1 2990 2996 2
WBS1 (PF) 2 7
1 2991 2997 2
3 8
RHS 4 1 293 190 2 9
1 2992
WBS3 (FF) 5 10
1 2993
A 6 11
12
13
297 3 14
290 2 15
592 2 16 C
PC209
1 CAN
190 22 INTERFACE #2
3 BACKREST
2994
2995
2996
2997
292 4
294
295
590
5
4 4 1 1 1 1 1 1 6
7
1 2 JC230 1 2 3 4 5 6 PC241 8 B
D WBS2 (PF) A
WBS4 (FF)
LHS
820541_2B_1
Contact pins Connector housing
Item No. Order Number Type Housing Order Number
1 792883 A PC224, PC225 792881-004

2 116858 Anti Back Out 793091-004
3 803450-049 B PC209 803450-008
4 792882 Sealing 819279-004
C PC207 116851
Sealing 819279-008
D JC230, JC231 792880-001
GPC3000
242
SCHEMATIC DIAGRAMS
Wire connections

No. No.
2990 CA207-1 CAN 290 SPLINE 1

Backr. PC207-15
PC225-2 WBS1
2991 CA207-2 CAN 291 SPLINE 1
Backr. PC225-1 WBS1
PC225-3 WBS1
2992 CA207-5 CAN 292 SPLINE 1
Backr. PC224-1 WBS2
PC225-4 WBS2
2993 CA207-6 CAN 293 SPLINE 1
Backr. PC225-4 WBS3
PC225-5 WBS2
2994 CA207-3 CAN 294 SPLINE 1
Backr. PC224-4 WBS4
PC224-2 WBS3
2995 CA207-4 CAN 295 PC207-14
Backr. JC230-1
PC224-3 WBS4
2996 CA207-7 CAN 296 PC207-14
Backr. JC231-1
PC224-4 WBS4
2997 CA207-8 CAN 590 PC207-16
Backr. JC230-2
PC224-5 WBS4
190 PC207-9 591 PC207-16
PC209-2 JC231-2
GPC3000
243
SCHEMATIC DIAGRAMS
Heater Assembly
Heater Assembly
PC230 (PC231)
PC408
RED
1
BLUE
2
820639_2B_1
Order number 820639-001
1 794611-005
Order number 820639-002
1 794611-006
Order Numbers 820639-001 & 820639-002
5 792881-001
6 792883
7 793091-001
GPC3000
244
SCHEMATIC DIAGRAMS
Connection Cable Alarm
Connection Cable Alarm
JC223
BLU BLU
Connected with 1 1 2 Connect with
BLK BLK
Main Harness A 2 1 2 Alarm
822337_XA_1
Contact pins
1 792882
2 816812-057
Connector housing
A JC223 792880-001
GPC3000
245
SCHEMATIC DIAGRAMS
Connection Cable DC / DC Converter
Connection Cable DC / DC Converter
JC239 PC240
BLU BLU
Connected 1 2 1 1 Connect with
BLK BLK
with Main B 2 2 1 2 A DC / DC
Harness Converter
822338_XA_1
Contact pins
1 792883
2 792882
Connector housing
A PC240 792881-001
B JC239 792880-001
GPC3000
246
SCHEMATIC DIAGRAMS
DC / DC Converter
DC / DC Converter
JC240
RED 1
1
BLU 1
2 A
BLACK
BROWN
822339_XA_1
Contact pins
1 792882
Connector housing
A JC240 792880-001
GPC3000
247
Notes:
248
HYDRAULIC SCHEMATIC
249
Notes:
250
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Hydraulic Symbols
Icon Meaning Icon Meaning
Vented reservoir with Electric motor unidi-

lines above the fluid rectional single speed
level
Vented reservoir with Hydraulic pump fixed

lines above the fluid displacement unidirec-
level tional
Filter or strainer Spring, (bias to normal

de-energised position)
Hydraulic line with full Solenoid single coil or

flow winding
Control line or drainage Component enclosure

with restricted flow manifold block
Lines crossing; not con- Resistor orifice throttle

nected (adjustable)
Lines crossing and con- Throttle, fixed

nected
Plugged port Relief valve adjustable
Accumulator gas Check valve

charged diaphragm
type
GPC3000 Rev.1 02/2009
251
HYDRAULIC SCHEMATIC
Hydraulic Symbols
2/2 way valve Hydraulic steer unit

(2 ways, 2 connections)
T L
P R
3/2 way valve Torque generator

P
T
3/2 way valve Shut-off valve, manual

(3 ways, 2 connections;
Spring bias solenoid
control
4/2 way valve Bypass flow control

(4 ways, 2 connections) with controlled flow,
pressure-regulated
4/3 way valve Flow divider/combiner

4/3 way valve Single pre-tension

(4 ways, 3 connections; valve assembly in
manual activation and manifold
spring centred
Flow meter Electric motor unidi-

rectional variable
speed
Rev.1 02/2009 GPC3000
252
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Valve block with Proportional solenoid

3 operating units
Shuttle valve Dual solenoid
Relief valve, fixed set- Hydraulic pilot

ting operated solenoid
valve
Velocity fuse Hydraulic pilot oper-

ated hydraulic valve
Pressure-compensated Manual actuator

flow control with
reverseflow bypass;
fixed.
Pressure-compensated Single-acting cylinder,

flow controll, fixed with cushion
Pilot check valve (pilot Single-acting cylinder

to open) ram type
Manual lever actuator Single-acting cylinder

with spring returned
(rod end vented)
GPC3000 Rev.1 02/2009
253
HYDRAULIC SCHEMATIC
Hydraulic Symbols
Double-acting cylinder; Thermometer

equal area
Double-acting cylinder; Pressure gauge

unequal area
Pressure switch Hydraulic motor,

bi-directional
Rev.1 02/2009 GPC3000
254
HYDRAULIC SCHEMATIC
GPC 3020
GPC 3020
SV1
RV1
GPC483
A Lift Cylinder
SV1 Lower Valve
RV1 Relief valve
GPC3000
255
HYDRAULIC SCHEMATIC
GPC 3040/3045/3060 without Platform, GPC 3055
GPC 3040/3045/3060 without Plat-

form, GPC 3055
M2
GPC483
A Lift Cylinder
SV Lower Valve
RV1 Relief Valve
PV Proportional "Lift" Valve
CV Check Valve
GPC3000
256
HYDRAULIC SCHEMATIC
GPC 3040/3045/3060 with Platform
GPC 3040/3045/3060 with Plat-

form
M2
GPC3085
A Lift Cylinder
B Platform Cylinder
SV1 Lift Lower Valve
SV2 Platform Lower Valve
PV Proportional Valve
CV Check Valve
RV1 Lift Relief Valve
RV2 Platform Relief Valve
GPC3000
257
Notes:
258

812571-006 RevB (GPC3000 Service)

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812571-006 RevB (GPC3000 Service)

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Available Formats

GPC3000 SERIES

Bestell Nummer: 812571-006

CROWN Gabelstapler GmbH & Co. KG

Phone +49 (0)89 93 00 2 – 0

All rights reserved under international and Pan-American Copyright Agreement.

SAFETY PAGE SERIAL NO. CUT REV.

INTRODUCTION PAGE SERIAL NO. CUT REV.

LUBRICATION & ADJUSTMENT PAGE SERIAL NO. CUT REV.

HYDRAULIC SYSTEM PAGE SERIAL NO. CUT REV.

DRIVE UNIT PAGE SERIAL NO. CUT REV.

ELECTRICAL SYSTEM PAGE SERIAL NO. CUT REV.

GPC 3045 with Platform Lift . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Steer Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

BRAKE SYSTEM PAGE SERIAL NO. CUT REV.

STEERING PAGE SERIAL NO. CUT REV.

Final tasks: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

LIFTING MECHANISM PAGE SERIAL NO. CUT REV.

CYLINDERS PAGE SERIAL NO. CUT REV.

PLATFORM PAGE SERIAL NO. CUT REV.

Replacing the Platform Sensors . . . . . . . . . . . . . . . . . . . . . . . 184

SCHEMATIC DIAGRAMS PAGE SERIAL NO. CUT REV.

Scissors RAS - LOS Assy GPC 3000 . . . . . . . . . . . . . . . . . . 237

HYDRAULIC SCHEMATIC PAGE SERIAL NO. CUT REV.

Symbols and Indicators General Symbols

Safety Symbols Fork direction

Before Parking the Truck

Before Working on the Truck

• Replace any faulty or missing decals.

General Using the Manual

Any modification which alters the original condition of

Lifting and Jacking

Lifting the Truck

Lifting the truck with a crane

Towing the truck

3. Attach the truck securely onto the forks of the truck

Jacking up the truck

Taking the Truck out of Service 5. Disconnect the battery.

If the truck is to be out of service for more than

Testing Re-Commissioned Trucks

Recommended Lubricants and An anti-corrosion fluid (Crown no. 805236-004) must

Type Lubricant Type Product Manufacturer Crown

Transmission oil Hyp 85W90 Aral

Type Lubricant Type Product Manufacturer Crown

Lubrication oil Essolube HDX+40 Esso

Lubricants Product Application Crown Part No.

Anti-corrosive agent Tectyl Corrosion inhibitor for cold store 805236-004

Position Component Lubri- Action 500 h 1000 h 5000 h

I-1 Truck, general Clean truck if necessary.

I-6 Steeringc Check operation. X/C

Position Component Lubri- Action 500 h 1000 h 5000 h

Position Component Lubri- Action 500 h 1000 h 5000 h

I-22 Pump Motor Check carbon brushes, springs and com-

Position Component Lubri- Action 500 h 1000 h 5000 h

I-37 Chain Pulley Yokem Check chain pulley yoke attachment.

GPC 3020/40/60 Inspection and

GPC 3045 Inspection and Lubri-

GPC 3055 Inspection and Lubri-

Standard Screws and Nuts

Grade: 8 and 8.87 10 and 10.9 12 and 12.9

Umbrako screws and nuts

Grade 10 and 10.9 12 and 12.9

General Oil Change

• Apply pressurised air to all hoses and lines before NOTE