Crown Forklift PTH50 SERIES Parts & Maintenance Manual 812752-006

PTH50 SERIES MAINTENANCE MANUAL AND PARTS CATALOG

M Order Number: 812572-006 Revision: A • Printed in Germany

This master manual is subject to continual updates.

It is intended solely for companies authorised by Crown.

The distribution of its content or copies thereof to third parties is prohibited.

Crown Gabelstapler GmbH & Co. KG - European Headquarters Moosacher Str. 52 80809 Munich Germany Tel: +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 2010 Crown Equipment Corporation

TABLE OF CONTENTS

I

Notes:

II

TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Text mark-ups in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Service personnel qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ordering documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Basic Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Personal safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Protecting the hazardous area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hazards from stored energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Restoring the truck to service after repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cleaning work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Handling batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Warning and instruction decals on the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Lifting gear and slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

LUBRICATION & ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cleaning the Truck and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Effects of incorrect cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Roller and slide bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Corrosion-protected surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Environmental protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cleaning the entire truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cleaning removed components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cleaning mechanical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Data plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PTH50 PS and S components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 PTH50 WS components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Lubricants and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Cold store application requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Abbreviations used in the table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Regular inspection in accordance with FEM 4.004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Planned Maintenance - PTH50, PTH50 GLV and PTH50 WS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Maintenance Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 PTH50 PS and S Planned Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Maintenance Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Inspection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

PTH50 Series

III

TABLE OF CONTENTS All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Troubleshooting (PTH50 PS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Actuating lever in neutral position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Approved hydraulic oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding hydraulic oil (all models except PTH50 PS and PTH50 S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding hydraulic oil (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adding hydraulic oil (PTH50 S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the hydraulic unit (all models except PTH50 PS and PTH50 S) . . . . . . . . . . . . . . . . . . . . . .

Hydraulic unit disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the hydraulic unit (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic unit disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the hydraulic unit (PTH50 S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic unit disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the Hydraulic Unit (all models except PTH50 S version 1) . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the piston ram and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the piston ram and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the control piston and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the valve cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repairing the Hydraulic Unit (PTH50 S version 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the piston ram and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the control piston and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and repairing the control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking the operation of the hydraulic unit relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the relief valve on the hydraulic unit (all models except PTH50 S version 2) . . . . . . . . . . . .

Repairing and adjusting the relief valve on the hydraulic unit (PTH50 S version 2 only) . . . . . . . . . . . .

Testing the relief valve on the hydraulic aggregate (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the relief valve on the hydraulic aggregate (PTH50 PS only) . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting the control piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Hydraulic Aggregate (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Pump Connecting Plate and Hydraulic Pump (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . .

Servicing the Hydraulic Aggregate (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the hydraulic filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the pressure filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the suction and return filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 29 29 29 29 32 32 32 33 34 35 35 35 35 35 35 36 36 36 36 37 37 37 38 38 39 39 39 40 43 43 43 43 43 44 44 45 45 45 46 47 47 47 47 47

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 On-Board Charger (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

PTH50 Series

IV

Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Battery (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Miscellaneous Electrical Components and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Fuses (PTH50 PS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 FU1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 FU2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 FU3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Emergency Disconnect switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Lift cutout on falling battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 PTH50 WS, Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 PTH50 WS - Weigher System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Standardised weighing scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Display resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Calibrating the 2100 Weighing Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Calibration stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Calculating the weighing curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Decision factor for 1-point or 3-point calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 1-point calibration of 2100 weighing scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 3-point calibration of 2100 weighing scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Calibrating the 4100 Weighing Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Calibration stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Calculate the weighing curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Decision factor for 1-point or 3-point calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 1-point calibration of 4100 weighing scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 3-point calibration of the 4100 weighing scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 PTH50 WS Weighing Scale, Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Most common error causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 No display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 No display despite buttons being pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Unstable display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Same weight raised several times shows different readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Weighing scale is inaccurate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Load Cell Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Load cell removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Load cell assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Repairing Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Wear test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Checking the contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Checking the coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Checking the springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Pump Motor (PTH50 S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Checking the carbon brushes and commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Checking the parking brake setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Adjusting the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

V

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Control Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Control handle assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Fitting the control chain and adjusting the control piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fork inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking forks for cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 89 89 89

CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic System Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Small hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Extractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Producing extractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Groove aligning arbor for small rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly devices for large rod seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protective mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod Seal Removal and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inserting a large rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fitting a small rod seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rod seal assembly, sealing lip first . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93 93 93 94 94 94 94 94 95 95 96 96 96 96 97 97

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Wire Colour Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General contact symbol abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PTH50 PS Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 102 104 106

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Hydraulic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 PTH50 PS Hydraulic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Important Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Truck modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Maintenance, repairs and training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Manual structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Abbreviations used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Hydraulic Unit PTH50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PTH50 PS Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump motor and pump PTH50 PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PTH50 PS Hydraulic Unit, Part 1 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VI

122 124 126 128

PTH50 PS Hydraulic Unit, Part 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 PTH50 S Hydraulic Unit, Version 1, Part 1 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 PTH50 S Hydraulic Unit, Version 1, Part 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 PTH50 S Hydraulic Unit, Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 PTH50 S Hydraulic Unit, Version 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 PTH50 WS Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 PTH50 PS Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

LIFTING MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 PTH50 Lifting Mechanism, Part 1 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 PTH50 Lifting Mechanism, Part 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 PTH50 Lifting Mechanism, Part 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 PTH50 Lifting Mechanism, Part 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 PTH50 Lifting Mechanism, Part 2 / 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Tandem Load Wheel PTH50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 PTH50 PS Lifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 PTH50 PS Lifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 PTH50 S Lifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 PTH50 S Lifting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Decals and Labels PTH50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Decals and Labels PTH50 PS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Decals and Labels PTH50 S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

VII

Notes:

VIII

INTRODUCTION

1

Notes:

2

INTRODUCTION Important Information

Important Information

Service personnel qualification

This maintenance manual details the maintenance and repair work to be carried out on the following truck models:

To maintain the safety and functionality of the truck, maintenance and repair work must only be performed by service engineers who have been authorised by Crown.

:

Contact Crown if you wish to have your engineers trained.

PTH50 PTH50 GLV

Ordering spare parts

PTH50 WS

Refer to the second part of this manual for the spare parts catalog. Always quote the following numbers when ordering spare parts:

PTH50 S PTH50 PS

Manual structure The manual is divided into the following sections:

•

Specification number

•

Model number

•

Serial number

These numbers can be found on the truck data plate.

Section

Note: Always use original Crown spare parts.

Index

Ordering documentation

Introduction

Parts catalogs, operator manuals, specification sheets etc. can be obtained from:

Safety Crown Gabelstapler GmbH & Co.KG Moosacher Str. 52 80809 Munich GERMANY

Lubrication & Adjustment Hydraulic System Electrical System Brake System

Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 or 133 www.crown.com

Steering Lifting Mechanism Schematic Diagrams Hydraulic Schematic

Text mark-ups in the manual The following symbols and mark-ups are used in the manual: 1., 2., 3. denote work steps to be taken.  This arrow indicates the consequences of an action.  This arrow indicates action to be taken to avoid hazards contained in a warnings.

(1), (2), (3) etc. indicate text references to item numbers in illustrations.

•

Indicates the first level in a list.

– Indicates the second level in a list.

Note: Where the word "Note" appears before text, this indicates important additional information.

PTH50 Series

Rev.2 02/2009

3

Notes:

4

SAFETY

5

Notes:

6

SAFETY Safety Notices

Safety Notices The following symbols will help you to assess the risk to yourself, other people and materials should you fail to comply with a safety notice:

DANGER This symbol warns of immediate danger to the life and health of personnel.

Severe injury or death will result.  Follow all instructions indicated by this symbol in order to avoid injury or death.

WARNING This symbol warns of potential danger to the life and health of personnel.

Severe injury or death may result.  Follow all instructions indicated by this symbol in order to avoid injury or death.

CAUTION This symbol warns of possible danger to the health of personnel.

Injury may result.  Follow all instructions indicated by this symbol in order to avoid injury.

CAUTION This signal word without a symbol warns of material damage.

Damage to the truck, tools and mechanisms may result.  Follow all instructions indicated by this signal word in order to avoid damage.

PTH50 Series

Rev.1 04/2009

7

SAFETY Basic Safety Notices

Basic Safety Notices

•

Organisational measures

Service personnel must stop work immediately if any unauthorised persons enter the hazardous area. These persons must be removed immediately.

•

Repair work must only be carried out by service engineers approved by Crown.

•

Work on electrical equipment must only be carried out by specialist electricians in accordance with electrical regulations.

•

High pressure hydraulic oil can cause severe injuries. Depressurise the hydraulic system before opening any sections of it.

•

Note the basic and action-specific safety notices in the respective chapters of this manual. Refer also to the truck operator manual, in particular the Safety chapter.

•

A 15 minute discharge time must be observed for the electrical energy stored in the capacitors and coils. Alternatively, these components can undergo a controlled discharge through an electrical resistor.

•

Service personnel must also observe statutory and other binding accident and environmental protection regulations.

•

•

The legal minimum age for performing repair work must be observed.

When carrying out work near the battery, always cover the battery terminals with a suitable insulating material (e.g. plywood board) to prevent short circuits.

•

Before carrying out work underneath and on raised components (e.g. fork carriages, extended mast stages, the truck itself), attach suitable safety devices and supports with sufficient capacity.

•

Springs and gas pressure dampers must be checked and slowly discharged before removing them.

•

Hazards from stored energy

Service personnel must be trained and authorised to operate industrial trucks and must be able to demonstrate their competence.

Personal safety equipment •

•

•

•

•

Always wear safety equipment such as safety shoes and goggles when carrying out maintenance and repairs. Depending on requirements you may also need to wear safety gloves and ear muffs.

When carrying out work on the hydraulic system, e.g. bleeding the system, wear suitable protective clothing such as safety gloves, goggles or a face mask.

Repair work •

Always carry out repair work in accordance with the test and maintenance schedule contained in this manual and any applicable service bulletins.

•

Before carrying out repair work prepare the truck as follows:

When handling batteries wear acid protective clothing such as safety gloves, goggles and an apron.

– Park the truck on a level surface – Lower the forks to the ground

Long hair, loose clothing and jewellery are prohibited. They could get caught or drawn in, resulting in injury. Do not wear jewellery especially when working on electrical systems, as a short circuit could cause burning.

– Switch off the truck and prevent it from being switched on again – Disconnect the battery and prevent the connector from being attached by unauthorised personnel.

•

When carrying out work that requires battery supply, jack up the truck until the drive wheel is clear of the ground.

•

Do not use a naked flame near the truck or to check fluid levels or for leaks.

When carrying out repair work that could be hazardous to yourself and other people, seal off a large part of the hazardous area with suitable marker tape.

•

Always have suitable fire protection equipment to hand when carrying out work.

•

Keep the truck clean; this makes it easier to find loose or missing components.

Before carrying out repair work, service personnel must ensure that there is no one in the hazardous area.

•

Welding work must only be carried out after prior consultation with Crown.

Always use insulated tools when working on electrical systems.

Protecting the hazardous area •

•

Rev.1 04/2009

8

PTH50 Series

SAFETY Basic Safety Notices •

Keep the work area clean and well lit. An untidy or poorly lit work area can lead to accidents.

•

Modifications to the original condition of the truck must be examined and approved in writing by Crown beforehand.

•

Always charge batteries in designated charging areas and make sure the area is well ventilated.

•

Remove battery acid stained clothing immediately.

•

Only use original Crown spare parts and accessories.

•

•

Never install or commission damaged components.

If acid comes into contact with the skin, rinse immediately with plenty of clean water. If it comes into contact with the eyes, rinse immediately with clean water for several minutes and then seek medical attention.

•

Immediately neutralize and thoroughly rinse any spilled battery fluid.

Restoring the truck to service after repair work •

•

After carrying out repairs refit any safety mechanisms that have been removed and make sure they are working correctly.

The truck may only be restored to service after repair work once all the truck functions have been successfully tested, in particular on the following components: – Brakes

suitable insulation (such as a plywood board) if you have to work in this area.

Warning and instruction decals on the truck •

In accordance with the test and maintenance intervals check that the warning and instruction decals on the truck are complete and legible.

•

Clean any dirty decals and replace any damaged or missing ones.

– Speed control

Note: The spare parts manual gives details of the labelling and position of the warning and instruction decals on the truck.

– Direction switches – Steering – Lifting mechanism •

– Warning devices (horn, warning indicator)

Lifting gear and slings

To avoid endangering other people, always test the truck in an open area where there are no other people or obstacles.

•

Always use suitable hoist devices and lifting gear with sufficient capacity.

•

Attach lifting gear to the designated strap points and prevent it from slipping. Make sure the lifting gear cannot touch other components during lifting.

•

Do not stand under a swinging load.

•

Repair work can only be performed under a raised truck if the truck has been protected against accidental lowering.

•

Work may only be performed on the chassis, fork carriage or mast if they have also been protected against accidental lowering.

•

Lifting gear such as load slings routed around sharp edges must be protected from cuts.

Cleaning work Particular care is required when cleaning the truck and components that have been removed. See page 13.

Handling batteries •

Batteries may only be charged, serviced or replaced by trained personnel. Observe the instructions contained in the operator manual, as well as the instructions of the battery and charger manufacturers.

•

The charger must be appropriate to the battery voltage and capacity. First connect the battery, then switch the charger on.

•

When handling batteries wear acid protective clothing such as safety gloves, goggles and an apron.

•

Do not use a naked flame and do not smoke when handling batteries.

•

Do not touch battery terminals with metal objects.

Cover the battery terminals with a

PTH50 Series

Rev.1 04/2009

9

SAFETY Basic Safety Notices Environmental protection •

Any work that involves environmentally hazardous substances being released must only be performed in designated areas, to allow hazardous chemicals and oils to be separated.

•

All substances released during maintenance and repair work must be collected in the proper manner and disposed of in accordance with national regulations. Oil filters and dehumidifying inserts must be treated as special waste.

•

Always act responsibly when carrying out repairs to avoid damaging the environment.

Rev.1 04/2009

10

PTH50 Series

LUBRICATION & ADJUSTMENT

11

Notes:

12

LUBRICATION & ADJUSTMENT Cleaning the Truck and Components

Cleaning the Truck and Components

Cleaning the entire truck 1. Park the truck in an area with an oil separator.

2. Switch off the truck, disconnect and remove the battery.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.

WARNING

 Observe the manufacturer’s safety instructions when handling solvents and lubricants.

Malfunctions when restarting the truck can cause serious injury Water can penetrate electrical components after steam cleaning or hose washing. This can accidentally trigger certain functions when the truck starts up again.

Effects of incorrect cleaning

 Do not steam-clean the truck or wash it down with a hose.

Electrical components Electrical components such as connectors, contacts, distributor boards, controllers and wiring can be damaged by water, cleaning agents and solvents.

Mineral and chemical residue that automatically remain on or in components after cleaning, are a cause of corrosion. This corrosion results in malfunctions and premature failure.

Roller and slide bearings Steam cleaning and solvents damage the lubricant film on bearing surfaces. This results in dry running and rapid damage to the bearing elements.

Corrosion-protected surfaces The brake lines, screw connections and shiny metal surfaces in particular on cold store trucks are factorytreated with an anti-corrosive agent (Anticorit BW 366®). This protection can be washed off by solvents and steam cleaning. The above-mentioned components will corrode as a result.

Cleaning the truck surface 3. Dry clean the truck. To do this use cloths, soft brushes (not metal brushes) and if necessary weak, dry compressed air.

Note: Local contamination that cannot be removed by dry cleaning can be treated with a damp cloth and a neutral cleaning agent. Make sure that neither water nor cleaning agent get into electrical components or bearings.

Cleaning electrical components 4. Clean electrical components only with weak, dry compressed air and a dry cloth.

After cleaning the truck 5. Wipe down the truck.

6. Remove any paint damage.

7. Add anti-corrosion agent if necessary.

Returning the truck to operation after cleaning Normally no special measures are required.

Environmental protection Cleaning must only be performed in specially designated areas to enable hazardous chemicals and oils to be separated.

Collect any waste (such as oily cleaning cloths) and dispose of them in accordance with local regulations.

If however there is a possibility that damp may have penetrated electrical components, proceed as follows: 1. Clean the truck with weak, dry compressed air and a cloth.

2. Leave the truck to stand for at least 30 minutes in a dry environment.

3. Insert the battery but do not connect it yet.

PTH50 Series

Rev. 1, Feb 09

13

LUBRICATION & ADJUSTMENT Cleaning the Truck and Components Note: Cleaned components must be dry and free of cleaning agent residue before being refitted, lubricated or painted.

WARNING Malfunctions when restarting the truck can cause serious injury Water or cleaning agent residue in electrical components can cause malfunctions when the truck is switched on.  You must be prepared to switch off the truck immediately with the Emergency Disconnect when the battery is connected and the truck is powered up.

5. Re-lubricate, paint or apply anti-corrosion agent to the components as required.

6. Refit the components.

7. For cold store trucks apply Anticorit BW 366® as an anti-corrosion agent for screw connections and shiny metal surfaces.

 Make sure that nobody can be injured by components accidentally starting up.

4. Connect the battery.

5. Switch on the truck.  If a function automatically starts, apply the Emergency Disconnect immediately.

Note: If possible, apply compressed air to the respective switch or connector. Repeat steps 1 to 5.  Is the starting pattern is normal, proceed to step 6.

6. Check all functions.

Cleaning removed components Cleaning mechanical components Components that have been removed can be steamcleaned under certain conditions.

CAUTION Steam-cleaning can damage electrical components and bearings  Mechanical components may only be steamcleaned if no electrical components or bearings are affected.

1. Components that have been removed should be cleaned by hand, ideally with warm water and a mild neutral cleaning agent.

2. If steam-cleaning cannot be avoided, it should be done without a cleaning agent. If grease needs to be removed, use a mild neutral cleaning agent.

Note: Steam-cleaning can remove anti-corrosion agent and paint from surfaces.

3. If a neutral cleaning agent has been used, rinse the components thoroughly with clear water.

4. Leave the cleaned components to dry thoroughly.

Rev. 1, Feb 09

14

PTH50 Series

LUBRICATION & ADJUSTMENT Components

Components Data plate The data plate is located on the back of the fork carriage.

15 14

1

13

2

1 12 3

11 4

10

5

9 6

Fig. 1 Data plate location 1

7

Data plate

8

PTH50 PS and S components Note: The term "hydraulic unit" designates the hydraulic and mechanical section with the pump piston and lift cylinder. The term "hydraulic aggregate" designates the electro-mechanical section with the pump motor, hydraulic pump and hydraulic reservoir.

Fig. 2 PTH50 PS 1

Hydraulic aggregate with pump motor, distributor plate and reservoir(a)

2

Oil filler neck(a)

3

Scissor mechanism

4

Charger(a)

5

Load wheels

6

Battery compartment and battery(a)

7

Stabiliser

8

Steered wheels

9

Hydraulic unit

10

Panel(a)

11

Emergency Disconnect(a)

12

Hydraulic cylinder

13

Control handle and controls

14

Piston ram

15

Fork carriage with forks (a). PTH50 PS only

PTH50 Series

15

LUBRICATION & ADJUSTMENT Components PTH50 WS components

1

2 4 3

Fig. 3 PTH50 WS components 1

Weigher display

2

Battery

3

Fork carriage

4

Fork shoes on the measuring cells

PTH50 Series

16

LUBRICATION & ADJUSTMENT Lubricants and Consumables

Lubricants and Consumables The following tables list lubricants and consumables that Crown uses in its factory. However, you can use any lubricants provided they meet the same technical criteria.

Cold store application requirements Special hydraulic oils, lubricants and grease must be used for cold store applications.

An anti-corrosion fluid (Crown no. 805236-004) must be applied to all machine parts such as screws, washers, nuts, pins, retaining rings etc.

Model B

BB D

Carefully protect all electrical connections and components against corrosion. For detailed information, refer to the Electrical System chapter.

Service intervals must be adapted to the conditions of use.

Abbreviations used in the table The lubricant type is indicated by letters. Individual letters (A, B, ...) denote lubricants for normal temperature ranges, double letters (AA, BB, ...) for low temperature ranges.

Lubricant Type

Product

Manufacturer

Grease (Multi-Purpose)

Aralube HLP2

Aral

LM Grease

Castrol

Regulus A2

Century

Beacon EP2

Esso

EP2

Maxol

Mobiluxe EP2

Mobil

Retinax LX

Shell

ALGWMI

SKF

Aralube SKL2

Aral

Unirex Lotemp EP

Mobil

Vitam GF 32

Aral

Hyspin AWS-32

Castrol

Nuto H32

Esso

DTE 24

Mobil

Tellus 32

Shell

Hydran LZ 32

Finol

B110

Fuchs Mineralölwerke GmbH

Low temperature grease

Hydraulic oil

DD

Hydraulic oil (low temp)

Deutz Oel HVI 32

Klockner

G

Lubrication oil

Essolube HDX+40

Esso

Kowal M 40

Aral

Delvac 1240

Mobil

GG

Low temperature lubrication Mobil SHC 626 oil

Mobil

Part No.

F806118

053002-005

---

053001-009

---

---

PTH50 Series

17

LUBRICATION & ADJUSTMENT Lubricants and Consumables Lubricants

Product

Application

Anti-corrosive agent

Anticorit BW 366®

Corrosion inhibitor for cold store trucks

805236-004

Rubber & Vinyl Dressing

Commercial

Rubber Components, Plastic Panels

-------------

PTH50 Series

18

Part No.

LUBRICATION & ADJUSTMENT Regular inspection in accordance with FEM 4.004

Regular inspection in accordance with FEM 4.004 Guideline FEM 4.004 “Regular Inspection of Industrial Trucks” requires the truck to be inspected by an expert.

This inspection must be carried out annually or in intervals as specified by the owner's risk analysis.

National regulations must be taken into account.

Exact details of intervals should be discussed with a Crown service engineer.

PTH50 Series

19

LUBRICATION & ADJUSTMENT Planned Maintenance - PTH50, PTH50 GLV and PTH50 WS

Planned Maintenance - PTH50, PTH50 GLV and PTH50 WS

non-corrosive environment. In dusty, environments it is reduced to 6 months.

corrosive

Maintenance Interval The maintenance interval for the PTH50, PTH50 GLV and PTH50 WS is 12 months when used in a clean,

I-2 I-1

L-1

L-4

I-6

I-3

I-5

L-3 I-4

Fig. 4 PTH50, PTH50 GLV and PTH50 WS inspection points

PTH50 Series

20

L-2

LUBRICATION & ADJUSTMENT Planned Maintenance - PTH50, PTH50 GLV and PTH50 WS Inspection points (See Fig. 4) Inspection points Index

Component

Check

I-1

Control handle

Check control handle for damage

I-2

Entry rollers, load wheels

Check for cracks and wear

I-3

Risers

Check for damage and wear

I-4

Steered wheels

Check wheels for cracks and wear

I-5

Hydraulic aggregate

Check for dirt, leaks and damage.

I-6

Forks and fork carriage

Check for cracks

---

Labels, decals

Check that they are all present and legible

Lubrication points (see Fig. 4).

See also the lubrication table on page 17.

Lubrication points Index

Model

Component

L-1, Fig. 6

B/BB

Lubricate the control handle detent ball area

L-2, Fig. 6

B/BB

Lubricate the risers

L-3, Fig. 6

B/BB

Lubricate the thrust bearings

L-4, Fig. 6

B/BB

Lubricate the pressure roller

PTH50 Series

21

LUBRICATION & ADJUSTMENT PTH50 PS and S Planned Maintenance

PTH50 PS and S Planned Maintenance Maintenance Interval The maintenance interval for the PTH50 PS and PTH50 S is 12 months when used in a clean, noncorrosive environment.

In dusty, corrosive environments it is reduced to 6 months.

I-7 I-1

I-6

Inspection points

L-4

(See Fig. 5) Inspection points

L-6

Index

Component

Check

I-1

Control handle

Check control handle for damage

I-2

Load wheels

Check for cracks and wear

I-3

Risers

Check for damage and wear

I-4

Steered wheels

Check wheels for cracks and wear

I-5

Hydraulic aggregate

Check for dirt, leaks and damage

I-6

Hydraulic unit(a)

Check for dirt, leaks and damage

I-7

Forks and fork carriage

Check for cracks

---

Labels, decals

Check that they are all present and legible

I-3

L-3

L-5 I-2

I-5 I-3 L-5 I-4 Fig. 5 PTH50 PS lubrication and inspection points

(a). PTH50 PS only

PTH50 Series

22

I-7

I-3 L-5

LUBRICATION & ADJUSTMENT PTH50 PS and S Planned Maintenance Lubrication points (See Figs. 5 and 6) See also the lubrication table on page 17.

Lubrication points Index

Model

Component

L-1, Fig. 6

B/BB

Lubricate the pressure roller

L-2, Fig. 6

B/BB

Lubricate the thrust bearings

L-3, Fig. 6

B/BB

Lubricate the scissor ball bearing races

L-4, Fig. 6

D/DD

Change the hydraulic oil (approx. 0.6 litres) and hydraulic filter(a)

L-5, Fig. 6

B/BB

Lubricate the risers

L-6, Fig. 6

B/BB

Lubricate the control handle detent ball area

L-1

L-2

(a). PTH50 PS only

Fig. 6 PTH50 PS lubrication points

PTH50 Series

23

LUBRICATION & ADJUSTMENT Troubleshooting

Troubleshooting All models Symptom

Possible Causes

Remedy

Forks do not raise with mechanical lift or forks lower automatically.

Control piston is misaligned.

Align the control piston.

Ball valve or gasket of valve cartridge is leaky or contaminated.

Try to flush out any contamination in the valve by pumping.

•

PTH50 S version 2 only: Disassemble the control valve, clean it and replace the seals.

Repair the pump cylinder.

Lift cylinder is leaky.

Repair the lift cylinder.

Relief valve is set too low.

Adjust the relief valve.

Try to flush out any contamination in the valve by pumping.

•

All, except for PTH50 S, version 2: Replace the valve cartridge if necessary.

•

PTH50 S version 2 only: Disassemble the control valve, clean it and replace the seals.

Control piston is misaligned.

Align the control piston.

Ball valve or gasket of valve cartridge is leaky or contaminated.

Try to flush out any contamination in the valve by pumping.

PTH50 Series

24

All, except for PTH50 S, version 2: Replace the valve cartridge if necessary.

Pump cylinder is leaky.

Forks raise when Ball valve or gasket of valve cartridge is pumped but lower again leaky or contaminated. when the control handle is moved down.

Forks do not lower.

•

•

All, except for PTH50 S, version 2: Replace the valve cartridge if necessary.

•

PTH50 S version 2 only: Disassemble the control valve, clean it and replace the seals.

LUBRICATION & ADJUSTMENT Troubleshooting Troubleshooting (PTH50 PS only) Symptom

Possible Causes

Remedy

Forks do not raise with mechanical lift or forks lower automatically.

Control piston is misaligned.

Align the control piston.

Ball valve or gasket of valve cartridge is leaky or contaminated.

Try to flush out any contamination in the valve by pumping. Replace the valve cartridge if necessary.

Pump cylinder is leaky.

Repair the pump cylinder.

Lift cylinder is leaky.

Repair the lift cylinder.

Relief valve is set too low.

Adjust the relief valve.

Forks raise when Ball valve or gasket of valve cartridge is pumped but lower again leaky or contaminated. when the control handle is moved down.

Try to flush out any contamination in the valve by pumping. Replace the valve cartridge if necessary.

Forks do not lower.

Control piston is misaligned.

Align the control piston.

Ball valve or gasket of valve cartridge is leaky or contaminated.

Try to flush out any contamination in the valve by pumping. Replace the valve cartridge if necessary.

Hydraulic aggregate leaks oil.

Oil level too high.

Correct the oil level

Leaky seal on hydraulic reservoir

Replace the seal.

Forks do not raise with electric lift.

FU1 or FU2 fuse blown.

Replace the fuse.

Emergency Disconnect faulty

Replace the Emergency Disconnect.

Integrated lift cutout faulty.

Replace charger.

RAS lift button faulty.

Replace the RAS lift button.

Broken wire in lift circuit

Test and replace the faulty wire.

Lift contactor faulty

Replace the contactor.

Battery voltage < 9.6 V.

Charge the battery.

Pump motor faulty

Replace the pump motor

Battery charging error

See error message table in the Electrical System chapter, page 52.

PTH50 Series

25

Notes:

26

HYDRAULIC SYSTEM

27

Notes:

28

HYDRAULIC SYSTEM Hydraulic Unit

Hydraulic Unit

The hydraulic oil continues to flow until the control handle reaches its lift limit.

Note: The hydraulic unit has the same function for all models. There are minor differences in the length of the piston rams (PTH50 S and PS) and the external hydraulic pressure port on the housing and on the cylinder tube on the PTH50 PS. Note: Two different hydraulic units are used on the PTH50 S. To distinguish them for the purposes of this manual and the parts manual we shall refer to them as “version 1” and “version 2”.

If the control handle is now moved down, the descending pump piston creates a back flow. This back flow closes the check valve (24). As a result the back flow to the reservoir is blocked. The pressure created opens the check valve (23). The hydraulic oil flows through the valve cartridge to the piston ram. The piston ram extends and the forks are raised.

When the control handle reaches its lower limit, the handle is raised again and the cycle repeats itself.

As the handle is raised, the lower check valve (23) in the valve cartridge closes and the hydraulic oil remains in the piston ram chamber.

Functional Description

Actuating lever in neutral position The camshaft (12) is rotated via a tie rod and chain connected to the actuating lever, and a reversing lever.

Starting from the "lift" position, the camshaft pushes the control piston down slightly. The upper check valve (24) is opened as a result, and is kept open by the control piston.

However, pumping with the control handle has no effect for the following reason: The hydraulic oil suctioned from the reservoir when the control handle is raised flows through the control piston chamber (25), via the upper check valve (24) into the valve cartridge (1) and on to the pump piston (9).

If the handle is now pushed down the hydraulic oil flows back to the reservoir via the same path, since the upper check valve is kept open by the control piston.

Lowering The camshaft (12) is rotated via a tie rod and chain connected to the selector, and a reversing lever.

Starting from the "neutral" position, the camshaft pushes the control piston down slightly. The upper check valve (24) opens the lower check valve (23) via a plunger.

Fig. 7 Control handle and selector 1

Control handle

2

"Lower" position

3

"Neutral" position

4

"Lift" position

This releases the path in the direction of flow and the hydraulic oil flows out of the lift chamber back to the reservoir. The piston ram (18) lowers.

Lifting (See Fig. 8) The camshaft (12) is rotated via a tie rod and chain connected to the selector, and a reversing lever. The control piston (26) extends fully via the spring (22) and releases the check valve (24).

If the selector is released, springs (5, 22) and the spring in the control handle restore all components to their previous positions.

When the control handle is raised the pump piston is pushed up by the spring (5). This suctions hydraulic oil out of the reservoir. The hydraulic oil flows via the upper check valve (24) through the valve cartridge (24) and on to the pump piston (9).

PTH50 Series

29

HYDRAULIC SYSTEM Hydraulic Unit

Fig. 8

Schematic diagram, cross section through hydraulic unit

PTH50 Series

30

HYDRAULIC SYSTEM Hydraulic Unit 1

Valve cartridge

2

Piston boss

3

Rod seal

4

Seal

5

Spring

6

Washer

7

Pump piston bracket

8

Retaining ring

9

Pump piston

10

Dowel pin

11

Control handle shaft

12

Camshaft

13

Seal

14

Retaining ring

15

Cylinder tube

16

Housing

17

Rod seal

18

Piston ram

19

Solenoid

20

Backring

21

O-ring

22

Spring

23

Check valve

24

Check valve

25

Chamber

26

Control piston

27

Dowel pin

28

O-ring

29

Deflector

30

Oil refill plug

31

Washer

32

Reversing lever

PTH50 Series

31

HYDRAULIC SYSTEM Service

Service

Adding hydraulic oil (all models except PTH50 PS and PTH50 S)

Approved hydraulic oils Application temperature

Product

Manufacturer

> 0 °C

Vitam GF 32

Aral

Hyspin AWS-32

Castrol

Nuto H32

Esso

DTE 24

Mobil

Tellus 32

Shell

Hydran LZ 32

Finol

B110

Fuchs Mineralölwerke GmbH

< 0 °C

Deutz Oel HVI 32 Klockner

1

Note: Other manufacturers' hydraulic oils can be used provided they have the same specification.

Fig. 9

Oil refill plug

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants.

Measuring the oil level 1. Fully lower the forks.

2. Remove the oil refill plug (1, Fig. 9) and the seal.

3. Insert a clean dipstick as far as the surface of the oil and measure the oil level from the surface to the top of the pump housing.  It should be 38 – 57 mm  If the oil level has fallen below 57 mm, add hydraulic oil.

PTH50 Series

32

HYDRAULIC SYSTEM Service Note: The difference between the minimum and maximum levels is approx. 135 ml.

Adding hydraulic oil (PTH50 PS)

Adding hydraulic oil 1. Remove the oil refill plug (1, Fig. 9) and the seal.

CAUTION Do not use brake fluid Brake fluid damages the seals in the hydraulic system.  Use Crown-approved hydraulic oils only.

2. Add hydraulic oil appropriate to the application temperature. For oil grades see page 32.

3. Replace the seal as required and re-fit the oil refill plug (1, Fig. 9).

1

4. Torque the oil refill plug to 25 ±2 Nm.

3

Fig. 10

2

Adding hydraulic oil

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

Checking the oil level 1. Fully lower the forks.

2. Remove the panel.

PTH50 Series

33

HYDRAULIC SYSTEM Service 3. Visually inspect the oil level:  The oil level (3, Fig. 10) is correct when the hydraulic oil is at the top of the filler neck (2).  If the oil level has fallen below this, add more hydraulic oil.

4. Add hydraulic oil appropriate to the application temperature up to the bottom mark of the filler bore. For oil grades refer to the table on page 32.

5. Refit and tighten the oil refill plug.

Note: The overall capacity is approx. 1 litre.

Adding hydraulic oil 4. Unscrew the cap (1, Fig. 10).

CAUTION Do not use brake fluid Brake fluid damages the seals in the hydraulic system.  Use Crown-approved hydraulic oils only.

5. Add hydraulic oil appropriate to the application temperature up to the top of the filler neck. For oil grades refer to the table on page 32.

6. Re-fit the cap.

Adding hydraulic oil (PTH50 S) CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

Checking the oil level 1. Fully lower the forks.

2. Unscrew the oil refill plug (see Fig. 14, page 41).

3. Visually inspect the oil level:  The oil level is correct when the hydraulic oil is at the bottom mark of the filler bore.  If the oil level has fallen below this, add more hydraulic oil.

Adding hydraulic oil

CAUTION Do not use brake fluid Brake fluid damages the seals in the hydraulic system.  Use Crown-approved hydraulic oils only.

PTH50 Series

34

HYDRAULIC SYSTEM Replacing the Hydraulic Unit

Replacing the Hydraulic Unit Replacing the hydraulic unit (all models except PTH50 PS and PTH50 S)

Replacing the hydraulic unit (PTH50 PS) Note: The term "hydraulic unit" designates the hydraulic and mechanical section with the pump piston and lift cylinder. The term "hydraulic aggregate" designates the electro-mechanical section with the pump motor, hydraulic pump and hydraulic reservoir.

Hydraulic unit disassembly

Hydraulic unit disassembly 2

3

2

1

1 3

Fig. 11 PTH50 hydraulic unit disassembly

1. Pump up the unladen forks as far as the stop.

2. Push a square wooden block underneath the forks.

Lower the forks until they are resting on the wooden block.

Fig. 12 PTH50 PS hydraulic unit disassembly

3. Remove the pin (2) from the chassis (2).

•

4. Set the selector to the "lower" position and hold it there. At the same time push the piston ram down into the cylinder housing until the ram is released from its receptacle in the chassis.

5. Remove the ball from its socket at the top of the piston ram.

Tools required: Solid square wooden block at least as long as the fork straddle.

Preparing to disassemble the hydraulic unit 1. Pump up the unladen forks as far as the stop.

2. Push the square wooden block between the scissor arms and the forks.

6. Remove the wheels and axle.

3. Lower the forks until they are resting on the wooden block.

7. Tilt the hydraulic unit towards the control handle and remove it.

4. Disassemble the hydraulic aggregate (see page 45).

Hydraulic unit assembly

Hydraulic unit disassembly

1. Assembly is the reverse of disassembly.

5. Remove the pin (2) from the chassis (2).

6. Set the selector to the "lower" position and hold it there. At the same time push the piston ram down into the cylinder housing until the ram is released from its receptacle in the chassis.

7. Remove the ball from its socket at the top of the piston ram.

8. Remove the wheels and axle.

9. Tilt the hydraulic unit towards the control handle and remove it.

PTH50 Series

35

HYDRAULIC SYSTEM Replacing the Hydraulic Unit Hydraulic unit assembly 1. Assembly is the reverse of disassembly.

Replacing the hydraulic unit (PTH50 S) Hydraulic unit disassembly 2 1 3

Fig. 13 PTH50 S hydraulic unit disassembly

Tools required: •

Solid square wooden block at least as long as the fork spread.

Preparing to disassemble the hydraulic unit 1. Pump up the unladen forks as far as the stop.

2. Push the square wooden block between the scissor arms and the forks.

3. Lower the forks until they are resting on the wooden block.

Hydraulic unit disassembly 4. Remove the pin (2) from the chassis (2).

5. Set the selector to the "lower" position and hold it there. At the same time push the piston ram down into the cylinder housing until the ram is released from its receptacle in the chassis.

6. Remove the ball from its socket at the top of the piston ram.

7. Remove the wheels and axle.

8. Tilt the hydraulic unit towards the control handle and remove it.

Hydraulic unit assembly 1. Assembly is the reverse of disassembly.

PTH50 Series

36

HYDRAULIC SYSTEM Repairing the Hydraulic Unit (all models except PTH50 S version 1)

Repairing the Hydraulic Unit (all WARNING

models except PTH50 S version 1) Replacing the piston ram and seals

Risk of injury from pre-tensioned springs Springs can snap off with extreme force.

(See Fig. 59, page 122)

 Be particularly careful when handling springs and wear protective goggles.

Note: For tools and the procedure for the safe removal and assembly of seals refer to the Cylinders chapter starting on page 93.

Disassembling the piston ram

2. Using a suitable lever press the springs (17) together, keep them compressed and remove the retaining ring (20).

1. Disassemble the hydraulic unit.

3. Slowly release the springs.

2. Remove the piston ram (1) from the top of the cylinder tube (4).

4. Remove the springs and pull up the pump piston (19) including everything attached to it.

3. Remove in turn the seal (2), retaining ring (3) and seal (5). Dispose of the seals.

CAUTION

Assembling the piston ram

Health risk Cleaning agents, lubricants and consumables can damage your health.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.

 Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

 Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

Removing the seals

1. Clean the metal parts, in particular the seal seats.

5. Remove and dispose of the seals (16, 15).

6. Remove the piston boss (14).

2. Apply a thin coat of hydraulic oil to the surfaces.

7. Remove and dispose of the O-ring (13) and deflector (12).

3. Pull new seals onto the ram and fit the retaining ring.

Assembling the pump piston

4. Insert the piston ram into the cylinder tube without damaging the seals.

1. Clean the metal parts, in particular the seal seats.

2. Apply a thin coat of hydraulic oil to the surfaces.

Replacing the piston ram and seals

3. Apply a thin coat of hydraulic oil to the new seals and install them.

(See Fig. 59, page 122)

4. Insert the pump piston without damaging the seals.

Note: For tools and the procedure for the safe removal and assembly of seals refer to the Cylinders chapter starting on page 93.

5. Refit the control handle.

6. Check operation.

Disassembling the pump piston

WARNING

1. Disassemble the control handle.

Risk of injury from pre-tensioned springs Springs can snap off with extreme force.  Be particularly careful when handling springs and wear protective goggles.

7. Refit the springs, washer and retaining ring.

PTH50 Series

37

HYDRAULIC SYSTEM Repairing the Hydraulic Unit (all models except PTH50 S version 1) Replacing the control piston and seals

(See Fig. 56, page 98) Disassembling the valve cartridge 1. Place the truck on its side, resting on cardboard.

(See Fig. 59, page 122) Note: For tools and the procedure for the safe removal and assembly of seals refer to the Cylinders chapter starting on page 93.

2. Unscrew the valve cartridge (11) and dispose of it together with all the seals.

Assembling the valve cartridge 1. Apply a thin layer of oil to the new seals from the seal kit and fit them on the new valve cartridge.

Disassembling the control piston 1. Disassemble the control handle.

2. Screw in the valve cartridge (11) and tighten it.

2. Remove the camshaft (9).

3. Remove the control piston (23) and springs (24).

4. Dispose of the O-ring (22) and deflector (21).

3. Stand the truck up again.

4. Check operation.

Assembling the control piston

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

1. Clean the metal parts, in particular the seal seats.

2. Apply a thin coat of hydraulic oil to the surfaces.

3. Apply a thin coat of hydraulic oil to the O-ring (22) and deflector (21) and assemble them.

4. Assemble the springs (24) and control piston (23) in position. Take care not to damage the seals in the process.

5. Refit the camshaft (9).

6. Refit the control handle.

7. Check operation and adjust the control piston if necessary (see page 44).

Replacing the valve cartridge CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

PTH50 Series

38

HYDRAULIC SYSTEM Repairing the Hydraulic Unit (PTH50 S version 2)

Repairing the Hydraulic Unit WARNING

(PTH50 S version 2) Replacing the piston ram and seals

Risk of injury from pre-tensioned springs Springs can snap off with extreme force.

(See Fig. 66, page 136)

 Be particularly careful when handling springs and wear protective goggles.

Note: For tools and the procedure for the safe removal and assembly of seals refer to the Cylinders chapter starting on page 93.

1. Remove the retaining ring (29) and shim (28).

2. Remove the pump cylinder (15) and spring (13).

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

Note: If the pump cylinder is difficult to remove (seals stick), exert slow and gentle pressure to the pump piston with the control handle; this will force the pump cylinder out of its housing.

3. Dismantle the pump cylinder further and dispose of the seals. Carefully dispose of any worn parts as well.

Assembling the pump piston 4. Clean the metal parts, in particular the seal seats.

Disassembling the piston ram

5. Apply a thin coat of hydraulic oil to the surfaces.

1. Disassemble the hydraulic unit.

6. Apply a thin coat of hydraulic oil to the new seals and install them.

2. Remove the piston ram (9) from the top of the cylinder tube (1).

3. Remove the metallic abrasion from the magnet (8).

4. Clean the metal parts, in particular the seal seats.

Disassembling the seals 5. Take off the retaining ring (6) and disassemble the spacer bushing (3), seal (4), guide bushing (5) and seal (7).

6. Dispose of the seals.

7. Clean and apply hydraulic oil to all components.

Assembling the seals

7. Refit the pump cylinder and spring.

Replacing the control piston and seals Note: For tools and the procedure for the safe removal and assembly of seals refer to the Cylinders chapter starting on page 93.

Disassembling the control piston 1. Disassemble the control handle.

2. Remove the camshaft.

3. Remove the control piston (31) and springs (32).

8. Apply a thin coat of hydraulic oil to the new seals and install them with the spacer bushing (3) and guide bushing (5).

4. Dispose of the O-ring (30).

Assembling the control piston

9. Fit the retaining ring (6) Assembling the piston ram 10. Apply a thin coat of hydraulic oil to the metal surfaces.

11. Insert a piston ram into the cylinder tube without damaging the seals.

CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

Disassembling the pump piston (See Fig. 63, page 112) Note: For tools and the procedure for the safe removal and assembly of seals refer to the Cylinders chapter starting on page 93.

1. Clean the metal parts, in particular the seal seats.

PTH50 Series

39

HYDRAULIC SYSTEM Repairing the Hydraulic Unit (PTH50 S version 2) 2. Apply a thin coat of hydraulic oil to the surfaces.

3. Apply a thin coat of hydraulic oil to the new seals and install them.

4. Insert the spring and control piston without damaging the seals.

5. Refit the camshaft.

6. Refit the control handle.

7. Check operation and adjust the control piston if necessary (see page 44).

Cleaning and repairing the control valves CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

(See Fig. 66, page 136) Disassembling the control valves 1. Unscrew the dummy plug (39).

2. Dispose of the seal (38).

3. Take all components out of the valve body bore, clean them and check for damage.

4. Replace any faulty components.

Assembling the control valves 1. Apply a thin coat of hydraulic oil to the clean components.

2. Assemble all components in the correct order.

3. Tighten the dummy plug (39).

4. Check operation.

PTH50 Series

40

HYDRAULIC SYSTEM Repairing the Hydraulic Unit (PTH50 S version 2)

1

2

8

3

9

7

6 5

4

13 14 17

15 10 11

16

12 12

Fig. 14 Cross section of hydraulic unit, PTH50 S, version 2 PTH50 Series

41

HYDRAULIC SYSTEM Repairing the Hydraulic Unit (PTH50 S version 2) 1

Camshaft

2

Control piston

3

Spring “Y”

4

Channel “C”

5

Spring “X”

6

Channel “B”

7

Spring “W”

8

Pump piston

9

Oil refill plug

10

Piston ram

11

Cylinder tube

12

Solenoid

13

Ball “L”

14

Plunger

15

Ball “N”

16

Ball valve “N & L”

17

Relief valve

PTH50 Series

42

HYDRAULIC SYSTEM Relief Valve

Relief Valve With the exception of the relief valve on the hydraulic unit of PTH50 S version 2, all relief valves on the hydraulic aggregates have a fixed setting and therefore cannot be adjusted.

Note: The term "hydraulic unit" designates the hydraulic and mechanical section with the pump piston and lift cylinder. The term "hydraulic aggregate" designates the electro-mechanical section with the pump motor, hydraulic pump and hydraulic reservoir.

Checking the operation of the hydraulic unit relief valve

Note: Count the number of turns until the screw is removed. On assembly insert the setscrew back to exactly the same depth. This will avoid having to keep re-setting the valve.

4. Remove the carrier (41) and ball (42).

5. Clean and apply hydraulic oil to all components.

Assembling the relief valve 1. Insert the ball (42) and carrier (41) into the valve channel (40) with the setscrew.

2. Screw in the setscrew (40) with the previously noted number of turns.

Adjusting the relief valve 1. Prepare a test load 10% heavier than the maximum permissible load (see capacity plate on the truck).

Note: Not available on all models.

Checking the setting 1. Prepare a test load 10% heavier than the maximum permissible load (see capacity plate on the truck).

2. Fully lower the forks.

2. Fully lower the forks.

4. Activate lifting with the control handle.  If the load is raised, lower it and unscrew the setscrew (40) slightly. Repeat the setting until you reach the point where test load cannot be lifted.

3. Insert the forks under the test load.

Note: The load should rest against the fork shank.

3. Insert the forks under the test load.

Note: The load should rest against the fork shank.

4. Activate lifting with the control handle.  The valve is working if the load is not raised.  If the load is raised, the valve is faulty. Replace the relief valve or, in the case of the PTH50 S version 2, dismantle and repair it.

5. Fit the dummy plug (39) with a new seal (38).

Replacing the relief valve on the hydraulic unit (all models except PTH50 S version 2)

Checking the setting

Testing the relief valve on the hydraulic aggregate (PTH50 PS)

Disassembling the relief valve

1. Prepare a test load with 10% more weight than the maximum permissible load (see capacity plate on the truck).

1. Disassemble the relief valve.

2. Fully lower the forks.

2. Dispose of the relief valve and seals.

3. Insert the forks under the test load.

Note: The load should rest against the fork shank.

Assembling the relief valve 1. Assemble a new relief valve with a new seal.

2. Check operation of the relief valve (see Checking the operation of the hydraulic unit relief valve).

4. Activate electrical lifting.  The valve is working if the load is not raised.  If the load is raised, adjust the relief valve on the hydraulic aggregate.

Repairing and adjusting the relief valve on the hydraulic unit (PTH50 S version 2 only) Disassembling the relief valve 1. Remove the dummy plug (39) and seal (38).

2. Dispose of the seal.

3. Remove the setscrew (40).

PTH50 Series

43

HYDRAULIC SYSTEM Relief Valve Adjusting the relief valve on the hydraulic aggregate (PTH50 PS only)

2. Activate electrical lifting.  The valve is working if the load can just be raised.  If the load cannot be raised, lower the forks and proceed to step 3.

3. Insert the screw (4) slightly.

1

4. Repeat steps 2 and 3 until the load can just be raised.

2

Adjusting the opening point

3

1. Insert the forks under a test load 10% heavier than the maximum permissible load.

2. Activate electrical lifting.  The valve is working if the load is not raised.  If the load is raised, lower the forks and proceed to step 3.

4

3. Slacken the screw (4) slightly.

5

4. Repeat steps 2 and 3 up to the point where the load cannot be raised.

6

Completing the adjustment 1. Torque the counternut (2) while securing the screw (3).

7

2. Refit the domed cap nut.

Adjusting the control piston 1. Adjust the control piston as indicated on page 85.

Fig. 15 Relief valve unit parts

Preparing to adjust 1. Unscrew the domed cap nut (1).

2. Hold the screw (4) with the screwdriver and loosen the counternut (2).

3. Slacken the screw (4) slightly.

4. Prepare a test load 10% heavier than the maximum permissible load (see capacity plate on the truck).

5. Prepare a test load with the maximum permissible load (see capacity plate on the truck).

6. Fully lower the forks.

Setting the upper limit of the operating capacity 1. Insert the forks under the load with the maximum capacity.

Note: The load should rest against the fork shank.

PTH50 Series

44

HYDRAULIC SYSTEM Replacing the Hydraulic Aggregate (PTH50 PS)

Replacing the Hydraulic Aggregate (PTH50 PS)

•

Flat tray with a minimum 1.4 litre capacity.

•

Solid square wooden block at least as long as the fork straddle.

The hydraulic aggregate (1, Fig. 16) is connected to the hydraulic unit via a hose on the pressure side. The return flow is via a hose connected to the cylinder tube.

Preparing the truck

The hydraulic aggregate consists of the following main components: •

Pump motor

•

Pump connecting plate and pump

•

Hydraulic oil reservoir

1. Place a flat tray underneath the work area.

2. Extend the lift cylinder as far as the stop.

3. Push the square wooden block between the scissor arms and the forks. Lower the forks until they are resting on the wooden block.

4. Lower the forks until they are resting on the wooden block.

Hydraulic aggregate disassembly 5. Press the Emergency Disconnect switch.

1

6. Unscrew the battery retainer.

7. Pull the battery forward by no more than 50 mm.

8. Disconnect the battery cables from the terminals.

9. Unscrew the panels.

CAUTION 2

Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

10. Disconnect all cable connections and hose connections from the hydraulic unit.

Note: Seal any open hydraulic ports immediately with dummy plugs.

11. Remove the screws (8) and take out the hydraulic aggregate and place it on the base.

Fig. 16 Hydraulic unit and hydraulic aggregate

Assembly

1

Hydraulic aggregate

1. Assembly is the reverse of disassembly.

2

Hydraulic unit

Note: The term "hydraulic unit" designates the hydraulic and mechanical section with the pump piston and lift cylinder. The term "hydraulic aggregate" designates the electro-mechanical section with the pump motor, hydraulic pump and hydraulic reservoir.

Disassembly Tools required: •

Suitable base on which to place the hydraulic unit, e.g. a heavy iron ring.

PTH50 Series

45

HYDRAULIC SYSTEM Replacing the Pump Connecting Plate and Hydraulic Pump (PTH50 PS)

Replacing the Pump Connecting Plate and Hydraulic Pump (PTH50 PS) Note: The hydraulic pump is not available as a single part.

Adding the hydraulic pump to the new pump connecting plate 1. Install the relief valve (15), breather (16) and pressure filters (17, 18) with new seals onto the pump connecting plate.

Refitting the hydraulic filter and reservoir 2. Attach new filter elements and secure the hoses.

(See Fig. 61, page 126)

3. Attach the hydraulic oil reservoir with the flange and seal and tighten the screws.

Attaching the motor

CAUTION

4. Grease the coupling (13) and secure the motor and coupling in the correct position on the pump connecting plate.

Health risk Cleaning agents, lubricants and consumables can damage your health.

5. Insert and tighten the screws (1).

 Observe the manufacturer’s safety instructions when handling solvents, lubricants and consumables.

Note: Make sure the terminal board is positioned correctly so that the power cables can be attached after assembly.

Hydraulic aggregate disassembly

 The hydraulic aggregate is ready for assembly in the truck.

1. Disassemble the hydraulic aggregate (see page 45).

Hydraulic aggregate assembly 1. Assemble the hydraulic aggregate (see page 45).

2. Drain the hydraulic oil via the filler neck.

2. Add hydraulic oil (for correct grade see page 33) and bleed the hydraulic system.

Removing the motor 3.

Remove the four screws (1) and lift up the motor.

Take care not to lose the coupling (13).

Removing the hydraulic filter and reservoir 4. Remove the screws from the hydraulic oil reservoir flange and remove the reservoir from below.

5. Undo the filter clamps (19, 20, 22) from the pump and pump connecting plate and pull off the hoses and filters.

6. Undo the clamps from the filters and pull out the filters.

7. Remove the relief valve (15), breather (16) and pressure filters (17, 18).  The pump connecting plate and hydraulic pump are now disassembled. All the parts required for the new pump connecting plate are now removed.

Bleeding the hydraulic system 1. Activate electrical lifting briefly while monitoring the hydraulic oil level in the reservoir.  When the hydraulic reservoir is almost empty, stop lifting and lower the forks.

2. If the oil bubbles, wait until the air has been bled from the hydraulic oil.

3. Check the hydraulic oil level and replenish if necessary (see page 33).

4. If necessary, repeat steps 1 to 3 until the oil level has been set correctly with the forks lowered.

8. Dispose of the old pump connecting plate and hydraulic pump, together with the used filters and seals.

9. Clean all components (apart from the motor).

PTH50 Series

46

HYDRAULIC SYSTEM Servicing the Hydraulic Aggregate (PTH50 PS)

Servicing the Hydraulic Aggregate (PTH50 PS) Replacing the hydraulic filter (See Fig. 61, page 126)

Replacing the pressure filter Note: When unscrewing the pressure filter, take care not to lose the ball of the check valve (18).

1. Unscrew the pressure filter (17).

2. Insert and tighten the new pressure filter.

Replacing the suction and return filters 1. Remove the panel.

2. Remove the screws from the hydraulic oil reservoir flange and remove the reservoir from below.

Note: The filters are contained in the funnel-shaped end pieces on the suction and return lines.

3. Undo the filter clamps.

4. Pull out and dispose of the filters.

5. Attach new filters and secure them with the clamps.

6. Refit the hydraulic oil reservoir with the flange and seal. Tighten the screws.

Replacing the hydraulic oil Note: The oil reservoir (approx. capacity 0.6 litres) does not contain a drain plug.

1. Remove the panel.

2. Remove the screws from the hydraulic oil reservoir flange and remove the reservoir from below.

3. Dispose of the hydraulic oil in the reservoir.

4. Clean the hydraulic oil reservoir.

5. Attach the hydraulic oil reservoir with the flange and seal and tighten the screws.

6. Add hydraulic oil (for correct grade see page 33).

PTH50 Series

47

Notes:

48

ELECTRICAL SYSTEM

49

Notes:

50

ELECTRICAL SYSTEM On-Board Charger (PTH50 PS)

On-Board Charger (PTH50 PS)

WARNING

BDI

9

Charging the battery

1

8

2

7

3

6

Electric shocks can be fatal If the on-board charger and/or the truck have become damp, you could be killed by an electric shock when you connect the charger.  Only charge the battery when the charger and truck are dry.  Always charge the battery away from cold stores in rooms that are dry and will remain so during charging.

5

4

CAUTION The charger can be damaged if supplied with the wrong input voltage.

Fig. 17 On-board charger 1

Battery discharge indicator, green LED

2

Battery discharge indicator, yellow LED

3

Battery discharge indicator, red LED

4

Fuse FU3, 15 A

5

Cold store socket with in-built fuse

6

Charge phase indicator, red LED

7

Charge phase indicator, yellow LED

8

Charge phase indicator, yellow LED

9

Mains control LED (green LED)

 Connect the charger only to a supply network with the voltage indicated on the data plate.

Charging the battery 1. Unwind the mains cable from its receptacle.

2. Check the mains cable and connector for damage and replace if necessary.

3. Insert the mains connector.  The charging operation starts.

As well as the actual charging section, the on-board charger of the PTH50 PS also provides the following functions: •

Battery discharge indicator

Frequent partial charging can damage the battery

– Green LED lit for 70 -100 % residual capacity

 Do not interrupt the charging operation; wait until the battery is fully charged.

– Yellow LED lit for 30 - 70 % residual capacity – Red LED lit for 10 - 30 % residual capacity Lift cutout for discharged battery

 The battery is fully charged when all 4 LEDs of the charge control and the green LED of the battery discharge indicator are lit (see table).

– Lifting is inhibited if VBatt < 9.6 V after a lift operation.

Note: A new battery requires approx. 5 -10 charge and discharge cycles to reach its full capacity.

– Red LED flashes when VBatt < 9.6 V •

CAUTION

– Lifting is inhibited when VBatt < 9.6 V and no lift operation has been performed for 30 min.

– Lifting is disabled while the charger is connected to the mains.

PTH50 Series

51

ELECTRICAL SYSTEM On-Board Charger (PTH50 PS)

Charger displays for a normal charging operation Mains supply

Volume charging

90% charge

Charging complete

Green LED

Yellow LED

Yellow LED

Red LED

On

Off

Off

Off

On

Off

Off

On

On

Flashing

Off

On

On

On

Flashing

On

On

On

Mode

Connected to mains supply

Flashes twice Battery detected

On

Comments

Connection to mains, but charging has not yet started.

Battery has been detected.

The red LED briefly lights up twice.

Constant voltage Charging phase at constant charge voltage has started.

Time-controlled charge

The time-controlled charge phase has started.

Buffering

The charging operation is now complete. The battery is buffered while the mains cable remains connected.

Error messages Charger error displays (LEDs light up twice a second) Mains supply

Volume charging

90% charge

Charging complete

Comment

Cause

Green LED

Yellow LED

Yellow LED

Red LED

Flashing

Off

Off

Off

Hardware monitoring

The hardware monitoring error protection circuit has applied.

Flashing

Flashing

Off

Off

CV timeout

Flashing signal off

Off Flashing

Off Flashing

Flashing signal off

No battery

Battery has not reached the charge end voltage within the time limit.

Battery is not connected or has been disconnected or shorted during charging.

The mains voltage has

Flashing signal off

Off Flashing

Flashing signal off

Off Flashing

Drop in mains voltage

dropped so far during charging that the charger could not supply any more

output current.

PTH50 Series

52

ELECTRICAL SYSTEM On-Board Charger (PTH50 PS) Charger error displays (LEDs light up twice a second) Mains supply

Volume charging

90% charge

Charging complete

Comment

Cause

Flashing signal off

Off Flashing

Off Flashing

Off

Current limit

The current limit has applied (excessive charge current).

Flashing

Off

Flashing

Off

Overvoltage

Battery voltage has exceeded the limit.

Flashing (in sequence)

Flashing (in sequence)

Flashing (in sequence)

Flashing (in sequence)

EEPROM error

Flashing signal Off

Off Flashing

Flashing signal Off

Off

The internal time limit of 38 hours for activating the Internal timeout time-controlled phase has been exceeded.

Flashing signal Off

Off

Off Flashing

Off

External current not caused by charger.

The EEPROM checksum is wrong or the charger is not

calibrated.

Current flow in load circuit,

PTH50 Series

53

ELECTRICAL SYSTEM Battery (PTH50 PS)

Battery (PTH50 PS)

Installing the battery

The battery is maintenance-free. Occasional dry cleaning of the surface is sufficient to avoid excessive self-discharge through leakage current.

1. Install the battery in the reverse order.

2. Charge the battery until the green LED on the battery discharge indicator lights up.

Note: The battery discharge indicator (= BDI) loses the last saved reading when a battery connecting cable is disconnected. Fully charge the battery to reset the display.

CAUTION Risk of damage when using a different battery or charger The internal charger is adapted to the maintenance-free battery item no. 818258.  Only use replacement batteries with part number 818258.  Charge the battery with part number 818258 only with the charger supplied.

Replacing the battery Removing the battery

WARNING Short circuits can cause fires  Disconnect the charger from the truck before removing the battery.  Unscrew the battery cables from the battery terminals before pulling the battery fully out of the truck.

1. Pump up the unladen forks as far as the stop.

2. Push a square wooden block underneath the forks.

Lower the forks until they are resting on the wooden block.

3. Press the Emergency Disconnect.

4. Pull fuse FU1 (on the right of the battery rear panel) out of the fuse holder.

5. Unscrew the battery retainer.

6. Pull the battery forward by no more than 5 mm.

7. Disconnect the battery cables from the terminals.

Removing the battery 8. Place a wooden block of the same height as the bottom of the battery compartment in front of the battery compartment.

9. Pull the battery fully out of its compartment onto the wooden block.

10. Pull the battery out with the wooden block.

PTH50 Series

54

ELECTRICAL SYSTEM Miscellaneous Electrical Components and Functions

Miscellaneous Electrical Components and Functions Fuses (PTH50 PS) Note: Always use original Crown fuses as replacements. Automotive fuses may look identical but lack the required 32 volt electric strength.

FU1 This fuse (80 A/32 V) protects the power part of the lift circuit.

FU2 This fuse (5 A/32 V) protects the lift control circuit.

FU3 This fuse (15 A/32 V) protects the charger output against short-circuits.

Emergency Disconnect switch When pressed, the Emergency Disconnect switch disconnects the battery from the truck.

Lift cutout on falling battery voltage A lift cutout function is incorporated in the charger. This protects the battery from fully discharging as well as the charger if lifting is activated during charging.

– Lifting is inhibited if VBatt < 9.6 V after a lift operation.

– Lifting is inhibited when VBatt < 9.6 V and no lift operation has been performed for 30 min.

– Lifting is disabled while the charger is connected to the mains.

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ELECTRICAL SYSTEM PTH50 WS, Electrical Components

PTH50 WS, Electrical Components 1

1

3 2

2

Fig. 19 Weighing scale display and battery 1

Display and control panel

2

Battery

Fig. 18 Load cells 1

Fork shoe

2

Chassis

3

Load cells

1

3

Fig. 20 Power pack, charger and battery 1

Power pack

2

Charger

3

Battery

PTH50 Series

56

2

ELECTRICAL SYSTEM PTH50 WS - Weigher System

PTH50 WS - Weigher System General The PTH50 WS is equipped either with the 2100 or 4100 weighing scale. The weighing scales differ in their scope and features. For more information refer to the operator manual.

Standardised weighing scales Only weighing scales with an in-built tilt sensor can be confirmed as standardised. The tilt sensor switches the weighing scale display off if the scale is at an angle > 2°.

Note: After calibration by the service engineer the system must be confirmed by a metrological institute (e. g. calibration service) as being standardised.

Displaying the check number When the weighing scale is switched on a check number is displayed. This check number is automatically adjusted after every calibration. For standardised systems this number is recorded by the calibration officer. This means that it is always possible to check if the system has been re-calibrated.

1. Switch the weighing scale off and on again.  The weighing scale shows in turn (example): – 8888.8 (checking the LCD segments) – P 7.3 (software version number) – 1342 (check number) – 1234.5 (or the weight in standard weighing mode when the truck is laden)

Display resolution The size of the display increments depends on the weight: •

From 0 to 200 kg the weight is displayed in increments of 0.2 kg.

•

From 200 to 500 kg the weight is displayed in increments of 0.5 kg.

•

From 500 to 2200 kg the weight is displayed in increments of 1 kg.

Changing the display range allows smaller weights to be weighed with a higher resolution.

Accuracy The weighing scale is accurate to ± 0.1% of the weighed weight.

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ELECTRICAL SYSTEM Calibrating the 2100 Weighing Scale

Calibrating the 2100 Weighing Scale Required tools Note: The absolute weight of the test weights is not critical. The test weights need only be reasonably precise and within the capacity of the truck.

The weighing scale is precise to ± 0.1 %. You must therefore assemble the test weights on a weighing scale with an accuracy greater than ± 0.1 %. Better still, use standardised test weights.

To calculate the weighing curve and to calibrate you need: •

Several test weights ranging from 200 to 2000 kg in increments of approx. 300 kg.

For 1-point calibration: •

1 test weight (weight ideally in the range of the largest error (see curves in Fig. 21) or in the weighing range in which the weighing scale is mainly used).

Fig. 21 Examples of various weighing curves

For 3-point calibration:

1

Weighing curve with linear error above the weighing range.

•

2

Weighing curve with non-linear error above the weighing range.

3

Ideal weighing curve (can only be attained theoretically)

3 test weights (approx. 200 kg, approx. 1100 kg and approx. 2000 kg).

Calibration stages The weighing scale is calibrated in the following stages: •

Calculate the weighing curve.

•

On the basis of the weighing curve decide whether 1-point or 3-point calibration is required.

CAUTION The calibration will be faulty if the electronics warm-up time is not observed

Calculating the weighing curve

 Wait 5 minutes after the weighing scale has been switched on. Then begin the calibration.

The weighing curve forms the basis for deciding which calibration method to use.

Preparatory measures

Theoretically, the ideal weighing curve (3, Fig. 21) is linear. However, due to component tolerances each weighing system has its own weighing curve (1 or 2, Fig. 21).

Note: The calibration should be performed where possible at room temperature (20 °C). If this is not possible, within the permissible operating temperature of -10 °C to +40 °C.

The aim of calibration is to bring values outside the 0.1% tolerance range (yellow dots in Fig. 21) back into range (light grey).

1. Park the unladen truck on a level surface (angle less than 1°).

1. Switch on the weighing scale.

2. Wait for 5 minutes.

Calculate the weighing curve 1. Place the first test weight (approx. 200 kg) on the centre of the forks and raise it.

2. Check the display and record any deviation from the rated value.

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ELECTRICAL SYSTEM Calibrating the 2100 Weighing Scale 3. Repeat steps 1 and 2 each with the next heaviest test weight until the entire measuring range has been covered.  The readings produce the system's weighing curve (see Fig. 21).  If the deviation lies within the tolerance range of ± 0.1% of the weighed weights, no calibration is required.  If the deviation lies outside the tolerance range of ± 0.1% of the weighed weights, depending on the error distribution a 1-point or 3-point calibration is required.

Decision factor for 1-point or 3-point calibration When is a 1-point calibration sufficient?

A 1-point calibration is generally sufficient if: •

The error extends linearly over the measuring range (1, Fig. 21).

•

All errors have the same prefix and there is only a minor percentage difference in amount of deviation (1, Fig. 21).

See 1-point calibration of 2100 weighing scale, page 60.

When is a 3-point calibration necessary?

A 3-point calibration is necessary if: •

The error extends in a non-linear progression over the measuring range (2, Fig. 21).

See 3-point calibration of 2100 weighing scale, page 61.

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ELECTRICAL SYSTEM Calibrating the 2100 Weighing Scale 1-point calibration of 2100 weighing scale CAUTION The calibration will be faulty if the electronics warm-up time is not observed  Wait 5 minutes after the weighing scale has been switched on. Then begin the calibration.

Deleting old calibration points Before calibrating with just one calibration point, the highest and second highest old calibration points must be set to zero: 3. Use the “▲” or “▼” key to scroll to the middle calibration point.  The middle LCD bar flashes.

4. Press the “O/T” key.  The first digit flashes.

Preparatory measures

5. Press “▲” or “▼” to set the value to zero.

Note: The calibration should be performed at room temperature.

6. Press the “O/T” key again.  The next digit flashes.

1. Park the unladen truck on a level surface (angle less than 1°).

7. Repeat steps 4 to 6 until all digits are at zero.  The highest LCD bar flashes and the maximum calibration reading is displayed.

2. Switch on the weighing scale.

8. Repeat steps 4 to 6 until all digits are at zero.

3. Wait for 5 minutes.

 The highest and second highest old calibration points are now set to zero.

9. Use the “▲” or “▼” key to scroll to the lowest calibration point.  The lowest LCD bar flashes.

Lifting a test load 10. Place the test load on the centre of the forks.

11. Press the “O/T” key briefly.  The system switches to input mode.  The first segment flashes.

Entering a new individual calibration point

Fig. 22 Display and keypad of 2100 weighing scale

12. Enter the first digit of the test load weight with the “▲” or “▼” key.

Calibrating the zero point 1. Press the “0/T” key for approx. 8 seconds.  The display counts backwards from AF 08 to AF 00.  The percentage of the adjusted weighing range is displayed. For example AP 6.4.  If this is greater than AP 20, this indicates a fault. Stop calibrating and troubleshoot the system (see page 69).  The zero point is now calibrated. The weighing scale switches back to standard weighing mode.

Switching the system to calibration mode 2. Press the “PT” key for approx. 18 seconds (for older systems approx. 8 seconds).  The display turns dark until the system enters calibration mode.  The system is in calibration mode. The display indicates the value of the first calibration point. The lowest LCD bar on the left display border flashes.

13. Press “0/T” to jump to the next segment and enter the 2nd digit.

14. Repeat steps12 to 13 until the test load weight has been entered.  The lowest LCD bar flashes again.

Note: You must fill all the segments with numbers. For example, 600 kg must be entered as “0600.0”.

Confirming the new calibration point 15. When the value has been entered correctly, press “0/T” for 3 seconds  The display counts backwards from AF 08 to AF 00 and the calibration point is accepted.

Exiting calibration mode 16. Use the “▲” or “▼” key to scroll until AP XX is displayed.  The percentage of the adjusted weighing range is displayed. For example AP 6.4.

17. Press the “O/T” until the display switches off.  1-point calibration is now completed.

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ELECTRICAL SYSTEM Calibrating the 2100 Weighing Scale 3-point calibration of 2100 weighing scale

Lifting the first test load 5. Place the first test load (approx. 200 kg) on the centre of the forks.

CAUTION The calibration will be faulty if the electronics warm-up time is not observed

6. Press the “O/T” key briefly.  The system switches to input mode.  The first segment flashes.

 Wait 5 minutes after the weighing scale has been switched on. Then begin the calibration.

Entering the first calibration point

Preparatory measures

8. Press “0/T” to jump to the next segment and enter the 2nd digit.

Note: The calibration should be performed at room temperature.

1. Park the unladen truck on a level surface (angle less than 1°).

2. Switch on the weighing scale.

7. Enter the first digit of the test load weight with the “▲” or “▼” key.

9. Repeat steps 7 to 8 until the test load weight has been entered.  The lowest LCD bar flashes again.

Note: You must fill all the segments with numbers. For example, 600 kg must be entered as “0600.0”.

3. Wait for 5 minutes.

Confirming the first calibration point 10. When the value has been entered correctly, press “0/T” for 3 seconds  The display counts backwards from AF 08 to AF 00 and the calibration point is accepted.  The middle LCD bar flashes and the old value for the 2nd calibration point flashes.

Lifting the second test load 11. Place the second test load (approx. 1100 kg) on the centre of the forks.

Fig. 23 Display and keypad of 2100 weighing scale

Entering the second calibration point

Calibrating the zero point 1. Press the “0/T” key for approx. 8 seconds.

12. Enter the first digit of the test load weight with the “▲” or “▼” key.

2. The display counts backwards from AF 08 to AF 00.

13. Press “0/T” to jump to the next segment and enter the 2nd digit.

3. The percentage of the adjusted weighing range is displayed. For example AP 6.4.  If this is greater than 20%, this indicates a fault.

Stop calibrating and troubleshoot the system (see page 69).

14. Repeat steps12 to 13 until the test load weight has been entered.  The middle LCD bar flashes again.

 The zero point is now calibrated. The weighing scale switches back to standard weighing mode.

Switching the system to calibration mode 4. Press the “PT” key for approx. 18 seconds (for older systems approx. 8 seconds).  The display turns dark until the system enters calibration mode.  The system is in calibration mode. The display indicates the value of the first calibration point. The lowest LCD bar on the left display border flashes.

Note: You must fill all the segments with numbers. For example, 600 kg must be entered as “0600.0”.

Confirming the second calibration point 15. When the value has been entered correctly, press “0/T” for 3 seconds  The display counts backwards from AF 08 to AF 00 and the calibration point is accepted.  The top LCD bar flashes and the old value for the 3rd calibration point flashes.

Lifting the third test load 16. Place the third test load (approx. 2000 kg) on the centre of the forks.

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ELECTRICAL SYSTEM Calibrating the 2100 Weighing Scale Entering the third calibration point 17. Enter the first digit of the test load weight with the “▲” or “▼” key.

18. Press “0/T” to jump to the next segment and enter the 2nd digit.

19. Repeat steps 17 to 18 until the test load weight has been entered.  The top LCD bar flashes again.

Note: You must fill all the segments with numbers. For example, 600 kg must be entered as “0600.0”.

Confirming the third calibration point 20. When the value has been entered correctly, press “0/T” for 3 seconds  The display counts backwards from AF 08 to AF 00 and the calibration point is accepted.

Exiting calibration mode 21. Use the “▲” or “▼” key to scroll until AP XX is displayed.  The percentage of the adjusted weighing range is displayed. For example AP 6.4.

22. Press the “O/T” until the display switches off.  3-point calibration is now completed.

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ELECTRICAL SYSTEM Calibrating the 4100 Weighing Scale

Calibrating the 4100 Weighing Scale Required tools Note: The absolute weight of the test weights is not critical. The test weights need only be reasonably precise and within the capacity of the truck.

The weighing scale is precise to ± 0.1%. You must therefore assemble the test weights on a weighing scale with an accuracy greater than ± 0.1%. Better still, use standardised test weights.

To calculate the weighing curve and to calibrate you need: •

Several test weights ranging from 200 to 2000 kg in increments of approx. 300 kg.

For 1-point calibration: •

1 test weight (weight ideally in the range of the largest error or in the weighing range in which the weighing scale is mainly used).

Fig. 24 Examples of various weighing curves

For 3-point calibration: •

3 test weights (approx. 200 kg, approx. 1100 kg and approx. 2000 kg).

Calibration stages The weighing scale is calibrated in the following stages: •

Calculate the weighing curve.

•

On the basis of the weighing curve decide whether 1-point or 3-point calibration is required.

Calculate the weighing curve The weighing curve forms the basis for deciding which calibration method to use.

Theoretically, the ideal weighing curve (3, Fig. 24) is linear. However, due to component tolerances each weighing system has its own weighing curve (1 or 2, Fig. 24).

The aim of calibration is to bring values outside the 0.1% tolerance range (yellow dots in Fig. 24) back into range (light grey).

CAUTION The calibration will be faulty if the electronics warm-up time is not observed  Wait 5 minutes after the weighing scale has been switched on. Then begin the calibration.

Preparatory measures Note: The calibration should be performed where possible at room temperature (20 °C). If this is not possible, within the permissible operating temperature of -10 °C to +40 °C. 1. Park the unladen truck on a level surface (angle less than 1°).

2. Switch on the weighing scale.

3. Wait for 5 minutes.

Calculate the weighing curve 1. Place the first test weight (approx. 200 kg) on the centre of the forks and raise it.

2. Check the display and record any deviation from the rated value.

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ELECTRICAL SYSTEM Calibrating the 4100 Weighing Scale 3. Repeat steps 1 and 2 each with the next heaviest test weight until the entire measuring range has been covered.  The readings produce the system's weighing curve.  If the deviation lies within the tolerance range of ± 0.1% of the weighed weights, no calibration is required.  If the deviation lies outside the tolerance range of ± 0.1% of the weighed weights, depending on the error distribution a 1-point or 3-point calibration is required.

Decision factor for 1-point or 3-point calibration When is a 1-point calibration sufficient?

A 1-point calibration is generally sufficient if: •

The error extends linearly over the measuring range (1, Fig. 24).

•

All errors have the same prefix and there is only a minor percentage difference in amount of deviation (1, Fig. 21).

See 1-point calibration of 4100 weighing scale, page 65.

When is a 3-point calibration necessary?

A 3-point calibration is necessary if: •

The error extends in a non-linear progression over the measuring range (2, Fig. 24).

See 3-point calibration of the 4100 weighing scale, page 67.

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ELECTRICAL SYSTEM Calibrating the 4100 Weighing Scale 1-point calibration of 4100 weighing scale

value of the first calibration point. The lowest LCD bar “e1” flashes.

Deleting old calibration points

CAUTION The calibration will be faulty if the electronics warm-up time is not observed

Before calibrating with just one calibration point, the highest (e3) and second highest (e2) old calibration points must be set to zero:

 Wait 5 minutes after the weighing scale has been switched on. Then begin the calibration.

5. Use the “▲” or “▼” key to scroll to the e2 calibration point.  The “e2” LCD bar flashes.

Preparatory measures

6. Press the “” key.  The last digit flashes.

Note: The calibration should be performed at room temperature.

1. Park the unladen truck on a level surface (angle less than 1°).

1. Switch on the weighing scale.

7. Press the “▲” , “▼” and “◄” keys to set the value to zero.

8. Press the “” key.

9. Use the “▲” or “▼” key to scroll to the e3 calibration point.  The “e3” LCD bar flashes.

2. Wait for 5 minutes.

10. Repeat steps 7 until all digits are at zero.

11. Press the “” key.  The old “e2” and “e3” calibration points are now set to zero.

12. Use the “▲” or “▼” key to scroll to the “e1” calibration point.  The display indicates the value of the first calibration point. The lowest LCD bar “e1” flashes.

Fig. 25 Display and keypad of 4100 weighing scale

Lifting a test load

Setting the zero point

13. Place the test load on the centre of the forks.

Note: The weighing scale must be in standard weighing mode, not batch counting mode 1. Press the “0” key for approx. 10 seconds.

14. Press the “” key.  The system switches to input mode.  The first segment flashes.

2. The display counts backwards from AF 08 to AF 00.

Entering a new individual calibration point

3. The percentage of the adjusted weighing range is displayed. For example AP 6.4.  If this is greater than 8%, this indicates a fault.

Stop calibrating and troubleshoot the system (see page 69).  The zero point is now calibrated. The weighing scale switches back to standard weighing mode.

Switching the system to calibration mode 4. Press the “T” key for approx. 10 seconds.  After 3 seconds the tare standard value is displayed.  After a further 7 seconds the system enters calibration mode. The display indicates the

15. Press the “▲” , “▼” and “◄” keys to enter the weight of the test load.

Note: You must fill all the segments with numbers. For example, 600 kg must be entered as “0600.0”.

Confirming the new calibration point 16. If the value has been entered correctly press the “” key.  The lowest LCD bar “e1” flashes.

17. Press the “” key for 3 seconds.  The display counts backwards from AF 08 to AF 00 and the calibration point is accepted.

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ELECTRICAL SYSTEM Calibrating the 4100 Weighing Scale Exiting calibration mode 18. Use the “▲” or “▼” key to scroll until AP XX is displayed.  The percentage of the adjusted weighing range is displayed. For example AP 6.4.

Checking and adjusting the gravitational value Note: Ask your metrological institute for the gravitational value at the weighing scales application site. The value will differ within a country. For example, in Munich the gravitational value is 9.8071 m/s2 but in Kiel it is 9.8145 m/s2.

1. Press the “” key.  The display shows the set gravitational value.

2. Press the “▲” , “▼” and “◄” keys to set the gravitational value if required.

3. If the value has been entered correctly press the “” key.  1-point calibration is now completed.

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66

ELECTRICAL SYSTEM Calibrating the 4100 Weighing Scale 3-point calibration of the 4100 weighing scale

value of the first calibration point. The lowest LCD bar “e1” flashes.

Lifting the first test load 5. Place the first test load (approx. 200 kg) on the centre of the forks.

CAUTION The calibration will be faulty if the electronics warm-up time is not observed  Wait 5 minutes after the weighing scale has been switched on. Then begin the calibration.

Preparatory measures Note: The calibration should be performed at room temperature.

1. Park the unladen truck on a level surface (angle less than 1°).

6. Press the “” key.  The system switches to input mode.  The first segment flashes.

Entering the first calibration point 7. Press the “▲” , “▼” and “◄” keys to enter the weight of the test load.

Note: You must fill all the segments with numbers. For example, 600 kg must be entered as “0600.0”.

Confirming the first calibration point 8. If the value has been entered correctly press the “” key.  The lowest LCD bar “e1” flashes.

1. Switch on the weighing scale.

2. Wait for 5 minutes.

9. Press the “” key for 3 seconds.  The display counts backwards from AF 08 to AF 00 and the calibration point is accepted.  The “e2” LCD bar flashes.

Lifting the second test load 10. Place the second test load (approx. 1100 kg) on the centre of the forks.

Entering the second calibration point 11. Press the “▲” , “▼” and “◄” keys to enter the weight of the test load.

Fig. 26 Display and keypad of 4100 weighing scale

Setting the zero point Note: The weighing scale must be in standard weighing mode, not batch counting mode 1. Press the “0” key for approx. 10 seconds.

Note: You must fill all the segments with numbers. For example, 600 kg must be entered as “0600.0”.

Confirming the second calibration point

2. The display counts backwards from AF 08 to AF 00.

12. If the value has been entered correctly press the “” key.  The “e2” LCD bar flashes.

3. The percentage of the adjusted weighing range is displayed. For example AP 6.4.  If this is greater than 8%, this indicates a fault.

Stop calibrating and troubleshoot the system (see page 69).

13. Press the “” key for 3 seconds.  The display counts backwards from AF 08 to AF 00 and the calibration point is accepted.  The “e3” LCD bar flashes.

 The zero point is now calibrated. The weighing scale switches back to standard weighing mode.

Lifting the third test load

Switching the system to calibration mode 4. Press the “T” key for approx. 10 seconds.  After 3 seconds the tare standard value is displayed.  After a further 7 seconds the system enters calibration mode. The display indicates the

14. Place the third test load (approx. 2000 kg) on the centre of the forks.

Entering the third calibration point 15. Press the “▲” , “▼” and “◄” keys to enter the weight of the test load.

Note: You must fill all the segments with numbers. For example, 600 kg must be entered as “0600.0”.

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ELECTRICAL SYSTEM Calibrating the 4100 Weighing Scale Confirming the third calibration point 16. If the value has been entered correctly press the “” key.  The “e3” LCD bar flashes.

17. Press the “” key for 3 seconds.  The display counts backwards from AF 08 to AF 00 and the calibration point is accepted.

Exiting calibration mode 18. Use the “▲” or “▼” key to scroll until AP XX is displayed.  The percentage of the adjusted weighing range is displayed. For example AP 6.4.

Checking and adjusting the gravitational value Note: Ask you metrological institute for the gravitational value at the weighing scales application site. The value will differ within a country. For example, in Munich the gravitational value is 9.8071 m/s2 but in Kiel it is 9.8145 m/s2.

1. Press the “” key.  The display shows the set gravitational value.

2. Press the “▲” , “▼” and “◄” keys to set the gravitational value if required.

3. If the value has been entered correctly press the “” key.  3-point calibration is now completed.

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ELECTRICS PTH50 WS Weighing Scale, Troubleshooting

PTH50 WS Weighing Scale, Troubleshooting

6. Check the charger.  If the charger is ok, proceed to step 9.  If the charger is faulty, proceed to step 10.

7. Replace the display PC board.

Most common error causes

8. Repair the wiring.

The most common error causes are:

9. Charge and insert a new battery.

•

10. Replace the charger.

Power supply – Empty battery – Faulty fuse

Unstable display

– Charger unit defective

Checking the electronic system for humidity

– Poor or broken contacts

1. Remove the cover.

– Jammed or damaged wires

2. Examine the electronic system for traces of humidity.  If there is humidity in the electronic system, proceed to step 3.  If no humidity can be detected refer to Checking the fork shoe can move freely, Checking the load cells, Checking the adjustment PC board.

– Humidity in the electronics or in the load cells •

Mechanical problems – Deviations and errors in reproduction due to loosened load cell attachment – Fork shoe contacting the chassis. Caused by damage or contamination (wooden splinters from pallets)

3. Dry the components with warm air.

No display despite buttons being pressed

4. Carry out a functional test.  If the display is still unstable, refer to Checking the fork shoe can move freely, Checking the load cells, Checking the adjustment PC board.

Checking the power supply and display PC board

Checking the fork shoe can move freely

1. Pull out the battery and check the fuse on the back.  Replace the fuse if faulty.  If the fuse is ok, proceed to step 2.

Note: Anything restricting the freedom of movement of the fork shoe will result in display errors. No part of the fork shoe must touch the chassis, not even under load.

2. Remove the cover.

1. Unscrew and lift off the fork shoe.

Note: Leave the weighing scale switched on for at least 3 minutes before checking the battery voltage. The voltage only drops if current is removed from the battery for a while.

2. Remove contamination (wood remains etc.).  Proceed to step 3.

No display

3. Using a multimeter measure the battery voltage at the terminals: It should be approx. 12 VDC.  If the voltage at the terminals is ok, proceed to step 4.  If the voltage is less than 12 VDC, proceed to step 5.

4. Measure the power supply on the display PC board connector.  If there is battery voltage, the wiring is ok.

Proceed to step 7.  If there is no supply, the wiring has been disconnected. Proceed to step 8.

5. Replace the battery with a charged battery.  If the display is working, proceed to step 6.  If the display is still off, proceed to step 7.

3. Check the fork shoe for deformation.  Is the fork shoe is damaged, proceed to step 4.  Is the fork shoe is not damaged, proceed to Checking the load cells, Checking the adjustment PC board.

4. Replace the fork shoe.

Checking the load cells 1. Disconnect all load cell wires.

2. Using an ohmmeter, measure the resistance of each wire individually against the chassis.  If the resistance reading on a wire is not endless (∞Ω), then either this load cell or its wiring is faulty. Proceed to step 3.  If the resistance on all load cells is endless (∞Ω), proceed to Checking the adjustment PC board.

3. Replace the affected load cell.

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ELECTRICS PTH50 WS Weighing Scale, Troubleshooting Checking the adjustment PC board

3. Check the fork shoe for deformation.  Is the fork shoe is not damaged, proceed to step 4.  Is the fork shoe is damaged, proceed to step 7.

1

4. Refit the fork shoe.

5. Raise a weight of at least 1500 kg and tare the load.  The display shows 0 kg.

6. Arrange for one person after another to stand on each of the 4 corners while monitoring the display.  If the difference in weight of the people in each corner is more than 1 - 2 kg, fork shoe displacement with heavy loads may be the cause. Proceed to step 7.

7. Replace the fork shoe and repeat steps 5 to 6.  If the deviation in the 4 corners is still too great, proceed to Checking the load cells for measurement errors.

Fig. 27 Adjustment PC board

1. Remove the adjustment PC board (1, Fig. 27) and bend it slightly.  If the display responds to this, the adjustment PC board is faulty. Proceed to step 2.  If the display does not respond, the display PC board is faulty. Proceed to step 3.

2. Replace the adjustment PC board.

3. Replace the display PC board.

Same weight raised several times shows different readings Checking the fork shoe can move freely Note: Anything restricting the freedom of movement of the fork shoe will result in display errors. No part of the fork shoe must touch the chassis, not even under load.

1. Unscrew and lift off the fork shoe.

2. Remove all contamination (wood remains etc.).  Proceed to step 3.

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ELECTRICS PTH50 WS Weighing Scale, Troubleshooting Checking the load cells for measurement errors 1. Dismantle the fork shoe.

1

1

Fig. 28 Inserting the screw to check the load cells

Fig. 29 Adjusting the load cells

2. Insert the screw in the stay bolt assembly hole of a load cell.

3. Place a 20 kg weight on the head of the screw.

5. Adjust the load cell (1, Fig. .29).  If the load cell cannot be adjusted any further, replace the load cell and repeat the adjustment.

Note: The weight should not rest on the chassis.

6. Repeat steps 2 to 4 for the remaining load cells.

4. Check the display.  The displayed weight should deviate by no more than 200 g. If the display is out of range, proceed to step 5.

Weighing scale is inaccurate Re-calibrating the weighing scale 1. Calibrate the weighing scale (see calibration instructions starting on page 58).

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71

ELECTRICAL SYSTEM Load Cell Replacement

Load Cell Replacement 1

Load cell removal Fork shoe removal

1

3 2

Fig. 30 Fork shoe removal

1. Switch off the weighing scale and remove the battery.

2. Place the truck on its side, resting on cardboard.

3. Remove the 4 nuts (1, Fig. 30).

Fig. 31 Load cells

4. Straighten up the truck and take off the fork shoe (1, Fig. 31) from the top.

Loosening the load cell attachment 5. Remove the screws (3, Fig. 31) of the respective load cell.

PTH50 Series

72

ELECTRICAL SYSTEM Load Cell Replacement

1

2

Fig. 32 Accessing the electronic system

Opening the electronic access cover and disconnecting the load cell 6. Remove the cover (2, Fig. 32).

7. Disconnect the connecting cable from the respective load cell.

8. Remove the load cell and connecting cable.

Note: Attach a threading aid to the wiring before pulling the connecting cable through. This will help to thread the connecting cable of the new load cell.

Load cell assembly 1. Assemble the new load cell in the reverse order of disassembly.

2. Calibrate the weighing scale.

PTH50 Series

73

ELECTRICAL SYSTEM Repairing Contactors

Repairing Contactors

contacts must not be treated, as this would cause them to wear even faster.

Checking the coils

CAUTION The use of other manufacturers' contactors can damage the truck The original contactors are designed for Crown trucks.  Only use original Crown contactors as replacements.  Do not change the place or the angle where they are positioned and do not change the wiring.

1. Using an ohmmeter measure the resistance between the connections on the coil (2).

Note: If there is a freewheel diode between the connections, desolder it on one side and then test the coil. Otherwise the results will be false.  If either an endless resistance or no resistance are recorded, the coil (2) is faulty and must be replaced.

Checking the springs

Wear test

1. Check the spring (1) for corrosion or discolouring caused by heat.  Replace any corroded or discoloured springs (1).

4

1 3

2

Fig. 33 Example of a contactor 1

Spring

2

Coil

3

Contact (moving)

4

Contact (fixed)

Checking the contacts 1. Check the silver coating of the contacts (3, 4).  If the silver coating has worn to the extent that the support material is visible, both contacts (3, 4) must be replaced.

Note: The contacts (3, 4) are subject to natural wear during operation. Blackened, tarnished or scarified

Rev.1 04/2009

74

PTH50 Series

ELECTRICAL SYSTEM Pump Motor (PTH50 S)

Pump Motor (PTH50 S) Checking the carbon brushes and commutator Preparation 1. Remove the commutator lid from the pump motor.

2. Remove the insulating protective cap.

Checking the carbon brushes 1. Remove the carbon brushes and check for wear (new length = 20 mm).  If the carbon brushes are less than 10 mm long, proceed to step 4.  If the carbon brushes are still considerably more than 10 mm long, proceed to step 2.

2. Check all carbon brushes for damage, burning, cracking and overheating.  Is a carbon brush is damaged, proceed to step 4.  If the carbon brushes are not damaged, proceed to step 3.

Checking the commutator Note: An evenly distributed layer on the brush surfaces is normal.

3. Check the commutator for unevenness or damage.

To do so, rotate the commutator.  If the commutator is ok, proceed to step 4.  Is the commutator is damaged, proceed to step 5.

4. Replace the entire carbon brush set.

5. Replace the entire motor.

Motor assembly 6. Fit the insulating protective cap.

7. Screw on the commutator bearing cover.

PTH50 Series

75

ELECTRICAL SYSTEM Pump Motor (PTH50 S)

Notes:

PTH50 Series

76

BRAKE SYSTEM

77

Notes:

78

BRAKE SYSTEM Parking Brake

Parking Brake

Adjusting the parking brake

Since the brake can only be used as a parking brake, there is practically no wear on the brake lining.

However, should the Bowden cable extend, adjustment may be required.

7

1

2

Note: This brake is used only to secure a truck that is stationary. It is not a service brake.

Checking the parking brake setting

1

2

3 4

3 6 5

6 10

7 9

8

5

4

Fig. 35 Brake drum components 1

Brake drum attachment dowel pin

2

Brake lever on the brake drum

3

Counternut

4

Bottom adjusting nut

5

Bowden cable

6

Bowden cable jacket

7

Axle attachment dowel pin

Adjusting the parking brake Fig. 34 Control handle components

1. Park the truck without load on a level surface.

1

Activating lever for hydraulic functions

2. Release the brake.

2

Catch

3. Undo the nut (10, Fig. 34) at the top of the Bowden cable.

3

Position of catch when locking button is not pressed

4

Parking brake lever, applied

5

Parking brake lever, released

6

Locking button for parking brake lever

7

Position of catch when locking button is pressed

8

Control handle

9

Bowden cable

10

Top adjusting nut

4. Undo the counternut (3, Fig. 35) and adjusting nut (4) at the bottom of the Bowden cable (6).

5. Tighten the adjusting nut until the brake lining is against the brake drum. Now turn back the adjusting nut 2 - 3 turns.

6. Pull up and release the brake lever several times to check if there is any clearance.

Checking the freedom of movement of the steered wheels

Checking the parking brake setting 1. Move the brake lever from the "applied" position to the "released" position.  The setting is correct if the brake lever cannot move more than 30°.  If the angle is greater than 30°, adjust the parking brake.

7. With the brake released, check if the steered wheels can rotate freely.

8. If the wheels are not free to move, turn the adjusting nut back slightly.

9. If the wheels are free to move, proceed to step 10.

PTH50 Series

79

BRAKE SYSTEM Parking Brake Checking the parking brake setting 10. Check the parking brake setting as described in the previous section.

Completing the parking brake setting 11. Tighten the counternut (3, Fig. 35) at the bottom of the Bowden cable.

12. Tighten the nut (10, Fig. 34) at the top of the Bowden cable.

PTH50 Series

80

STEERING

81

Notes:

82

STEERING Control Handle

Control Handle Control handle assembly To assemble the control handle and adjust the control chain you need the following tools:

8 1

6 2 4 3 5 Fig. 36 Recommended tools

Fig. 38 Control chain position

1

Guide tool (part no. 044866)

2. Position the control chain (8) above the roller.

2

Punch 4 mm

3

Scriber

4

Long-nosed pliers

5

Long 3 mm hex. key wrench

6

Hammer

10 9 1

Control handle assembly

7

Fig. 39 Aligning the control handle

3. Insert the control handle (10) into the pump unit (9) and align the holes with the guide tool (1).

Fig. 37 Greased bearing bushings

1. Apply grease type B or BB to the bearing bushings (7) on the control handle.

PTH50 Series

83

STEERING Control Handle

12

1

13

15

16 18 19

Fig. 40 Inserting the axle Fig. 42 Threading the control chain

4. Position the axle (12) in such a way that the recess (13) is facing up and hole (15) is flush with hole (16). Manually insert the axle as far as it will go.

2. Guide the control chain (18) through the recess in the axle.

5. Remove the guide tool (1) and carefully strike the axle with the hammer until it is fully inserted.

3. Push the selector (1, Fig. 41) down and hold it there.

6. Using the 4 mm punch align the holes (15, 16) exactly for the dowel pin.

7. Drive the dowel pin into the hole.

4. Fit the punch in the hole of the camshaft (19). Turn the camshaft so that the hole in the camshaft is aligned with the chain anchor of the control chain.

 The control handle is now assembled. Proceed to "Fitting the control chain and adjusting the control piston".

20

Fitting the control chain and adjusting the control piston Fitting the control chain

1

Fig. 43 Inserting the control chain mounting screw

5. Guide the screw (20) with a long 3 mm hex. key wrench through the camshaft and insert it into the chain anchor.

6. Tighten the screw (20) while holding the chain anchor tight on the opposite side.

Fig. 41 Control lever

7. Set the control lever (1, Fig. 41) to the "Raise" position.

1. Pull the control lever (1) up.

PTH50 Series

84

STEERING Control Handle 12. Set the control lever (1, Fig. 41) to neutral and apply a few pumps of the control handle.  The forks should not raise.  If they do, repeat steps 9 to 12. While doing so, in step 10 always move the screwed nipple by just half a turn.

4

Fig. 44 Applying the long-nosed pliers

8. Position the long-nosed pliers (4) above the chain and below the plastic washer and spring in order to push the tie rod up.

23

a Fig. 45 Screwed nipple

9. Push the long-nosed pliers down to release the screwed nipple (23) in the recess on the control lever.

Adjusting the control piston 10. Using the scriber turn the screwed nipple (23) and set it so that dimension a = 10 mm.

Fig. 46 Screwed nipple in seat

11. Position the screwed nipple (23) in the recess in the control lever (1, Fig. 41).

PTH50 Series

85

Notes:

86

LIFTING MECHANISM

87

Notes:

88

LIFTING MECHANISM Forks

Forks General The forks must be checked by trained personnel for cracks, damage and wear in accordance with the maintenance schedule.

If the forks are used to transport abrasive loads the inspection must be carried out at shorter intervals.

Fork inspection WARNING Falling loads can cause injury If a fork breaks under load it can fatally injure you or other people.  Never carry out repair welding to surface cracks, damaged or worn parts.  Forks must only be repaired by the fork manufacturer.

Checking forks for cracks Visually inspect all fork surfaces for cracks. Particular attention should be paid to the weld seams. If in doubt carry out a non-rupturing crack test (paint penetration process or Magnaflux®).

Checking forks for cracks 1. Check the welding seams between the forks, fork carriage and fork shank for cracks.  Replace the forks if any cracks are detected.

PTH50 Series

89

Notes:

90

CYLINDERS

91

Notes:

92

CYLINDERS General

General

•

Always replace all the seals on the assembly. Used seals can cause leaks.

Safety Notices CAUTION Health risk Cleaning agents, lubricants and consumables can damage your health.  Observe the manufacturer’s safety instructions when handling solvents and lubricants.

WARNING High-pressure hydraulic oil can cause severe injury Whenever a high pressure hydraulic oil enters the skin it must be treated as a medical emergency.

Seek medical assistance even if the skin appears normal at first.

To avoid accidents: • Depressurise the hydraulic system before opening any sections of it.

• Tighten all connections before pressurising the system.

• Keep hands and body away from pressurized fluid.

•

Always use a piece of paper or cardboard to trace leaks.

Hydraulic System Repair Instructions •

Hydraulic systems are sensitive to dirt.

•

Thoroughly clean disassembled hydraulic components before dismantling them.

•

Always repair hydraulic components at a clean workstation.

•

Immediately protect cleaned and de-greased components with a thin coating of hydraulic oil.

•

Protect components against re-contamination before assembling them.

•

Immediately seal open hydraulic ports on repaired assemblies with dummy plugs. This also applies to open ports and lines on the truck.

•

Do not refinish any cylinder surfaces. Replace any damaged parts.

PTH50 Series

93

CYLINDERS Tools

Tools

Producing extractors 1. Hard solder a self-tapping 4 mm screw (3) onto the shaft (min. 150 mm, long, max. Ø 4 mm) of a screwdriver (1).

CAUTION Cylinder surfaces can be damaged through the use of unsuitable tools.

2. Sand the soldering joint.

 Do not use a screwdriver or similar tools.

3. Wrap insulating tape (1) around the shaft and soldering joint of the screwdriver.

 Use burr-free tools made of soft metal (brass, aluminium) without sharp edges or a suitable plastic.

Groove aligning arbor for small rod seals

You must produce the following tools yourself:

The outer diameter of the groove aligning arbor must fit the internal diameter of the cylinder cap.

Small hook

The arbor should end flush with the bottom of the seal seat.

Use small hooks to remove small seals (see Fig. 47).

1 2

3 Fig. 49 Groove aligning arbor in a cylinder cap

Fig. 47 Hook

1

Cylinder cap

2

Seal seat

3

Groove aligning arbor

Extractor Two extractors to remove rod seals (see Fig. 48) .

1

3

2

Fig. 48 Extractor

PTH50 Series

94

CYLINDERS Tools Assembly devices for large rod seals Produce a tool body (12, Fig. 50) with a diameter to match the internal diameter of the cylinder caps.

1

2

3 4

Fig. 50 Assembly device for large rod seals 1

Tool body

2

Fixed pin

3

Rod seal (shown for illustration purposes only)

4

Axial moving pins

Protective mechanisms If the seal has to be pushed over sharp edges, cracks or nicks, use appropriate plastic protective mechanisms.

PTH50 Series

95

CYLINDERS Rod Seal Removal and Assembly

Rod Seal Removal and Assembly

1

Removing a large rod seal

2 3

1. Turn one extractor (see Fig. 48) respectively into the opposite parts of the rod seal.

4

2. Pull the seal out of its seat using the grips of the tools.

3. Dispose of the rod seal.

Removing a small rod seal

5

1. Using a small hook (see Fig. 47) pull the rod seal out of the seal seat.

6

2. Dispose of the rod seal.

Inserting a large rod seal 1. Apply a thin coating of hydraulic oil to the rod seal and the seal seat in the cylinder cap.

2. Place the rod seal over the fixed pin (1, Fig. 51).

3. Bend the rod seal under the pin (2).

4. Now bend the resultant loop up so that the pin (3) can be moved into the loop.

Fig. 52 Wound rod seal

5. Push the tool body (1, Fig. 5) into the cylinder cap (2) until the rod seal (6) is aligned with the seal seat in the cylinder cap.

6. Retract the pin (1, Fig. ,53).  One segment of the rod seal jumps into the seal seat.

1

1

2

2 Fig. 51 Threading the rod seal

Fig. 53 The first rod seal segment is located in the seal seat.

7. Retract the pin (2, Fig. 53).  The rod seal is now fully located in the seal seat (see Fig. 54)

PTH50 Series

96

CYLINDERS Rod Seal Removal and Assembly Rod seal assembly, sealing lip first The sealing lip is sensitive and must not be damaged.

Special protective sleeves (1) are required when pushing the seal (2, Fig. 56) over the thread and holes.

CAUTION Incorrectly assembled rod seals will leak  Fit the rod seal with the sealing lip facing the pressure side.

3

1

2

Fig. 54 Rod seal fully inserted in seal seat

4

8. Pull the tool body out of the cylinder cap.

Fitting a small rod seal 6 1

5 2 3 Fig. 56 Sealing lip facing the pressure side

4

1

Cylinder tube

2

Inner thread

3

Protective sleeve for assembly

4

Rod seal

5

Sealing lip

6

Backring

Fig. 55 Small rod seal assembly

1. Apply a thin coating of hydraulic oil to the rod seal (2, Fig. 55) and the seal seat (3) in the cylinder cap (1).

2. Place the cylinder cap on the groove aligning arbor (4).

3. Gently bend the rod seal (2) together.

4. Place one part of the rod seal into the seal seat (3).

5. Press the rod seal into the seal seat using a burrfree aluminium or plastic arbor (1).

PTH50 Series

97

Notes:

98

SCHEMATIC DIAGRAMS

99

Notes:

100

SCHEMATIC DIAGRAMS Wire Colour Code

Wire Colour Code The wires used in the truck are colour-coded and numbered according to their function:

•

The first or first two digits designate the wire colour.

•

The last two digits are a sequence number.

Note: Third party component wires may pose an exception to this rule:

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 **

Miscellaneous

RED / WHT

Red/White

29 **

Positive connected

GRN / WHT

Green/White

59 **

Negative connected

** Numbers 01 to 99

PTH50 Series

Rev.1 02/2009

101

SCHEMATIC DIAGRAMS General contact symbol abbreviations

General contact symbol abbreviations Note: If one of the above abbreviations is used more than once, a number extension will be used, e.g. SV1, SV2 etc.

Abbreviati on

Description

Abbreviation

Description (Sheet 1 of 2)

K

Relay

LMS

Limit switch

ACS

Travel switch

LOS

Lower switch

AXS

Accessories switch

ORS

Override switch

BRS

Brake switch

POT

Potentiometer

DIS

Direction switches

RA

Raise potentiometer

DRS

Door switch

RAS

Lift switch

EDS

Emergency Disconnect

REA

Reach potentiometer

EM

Encoder module

RS

Reverse switch

ENC

Encoder

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

Thermal 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

Rev.1 02/2009

102

PTH50 Series

SCHEMATIC DIAGRAMS General contact symbol abbreviations Abbreviati on

Description

Abbreviation

Description (Sheet 2 of 2)

PLS

Platform switch

TCM

Traction motor

PS

Pressure switch

HR

Heating

HCM

Hydraulic control module

ALM

Travel Alarm

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

---

---

PTH50 Series

Rev.1 02/2009

103

SCHEMATIC DIAGRAMS Electrical wiring diagrams

Electrical wiring diagrams 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

Rev.1 02/2009

104

Assembly

Thermal protector

Contact, normally open

Lamp

Contact, normally closed

Horn

Selective switch

Battery

Contactors / relays

Diode

Slow release contactor / relay

Breakdown diode

Time delay contactor / relay

LED

Switch, normally open

Transistor

PTH50 Series

SCHEMATIC DIAGRAMS Electrical wiring diagrams Europe

USA

Description

Europe

USA

Description

Push button, mechanically actuated

MOSFET

Pushbutton, hydraulically actuated

Thyristor

Emergency Disconnect

Comparator

Motor armature ---

PTH50 Series

Rev.1 02/2009

105

SCHEMATIC DIAGRAMS PTH50 PS Wiring Diagram PTH50 PS Wiring Diagram

1

2

M 3

P

RAS

FU2 5A

4

P

5

ED

6

7

8

9 L

N PE

FU3 15 A 10

FU1 80 A

12 V 11

Fig. 57 PTH50 PS Wiring Diagram 1

Power cable (order no. 045983-003)

2

Power cable (order no. 045983-004)

3

Power cable (order no. 045990-001)

4

Power cable (order no. 045990-002)

5

Power cable (order no. 045984)

6

Charger: contains BDI (2), lift cutout electronic switch (2), mains socket (3) and charging section (4).

7

BDI and lift cutout electronic switch for when voltage falls below discharge terminal level.

8

Mains socket, internally protected with FU4 micro fuse (3,15 A / T)

9

Power cable (order no. 045983-002)

10

Charging section (logic and power part)

11

Power cable (order no. 045983-001)

PTH50 Series

106

HYDRAULIC SCHEMATIC

107

Notes:

108

HYDRAULIC SCHEMATIC Hydraulic Symbols

Hydraulic Symbols Icon

Meaning

Icon

Vented reservoir with lines above the fluid level

Meaning

Electric motor unidirectional single speed

Vented reservoir with lines above the fluid level

Hydraulic pump fixed displacement unidirectional

Filter or strainer

Spring, (bias to normal de-energised position)

Hydraulic line with full flow

Solenoid single coil or winding

Control line or drainage withrestricted flow

Component enclosure manifold block

Lines crossing; not connected

Resistor orifice throttle (adjustable)

Lines crossing and connected

Throttle, fixed

Plugged port

Relief valve adjustable

Accumulator gas charged diaphragm type

Check valve

PTH50 Series

Rev.1 02/2009

109

HYDRAULIC SCHEMATIC Hydraulic Symbols Icon

Meaning

Icon

Meaning

2/2 way valve (2 ways, 2 connections)

Hydraulic steer unit L R

T P

3/2 way valve (3 ways, 2 connections)

Torque generator P T

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

Shut-off valve, manual

4/2 way valve (4 ways, 2 connections)

Bypass flow control with controlled flow, pressure-regulated

4/3 way valve (4 ways, 3 connections)

Flow divider/combiner

4/3 way valve (4 ways, 3 connections; manual activation and spring centred

Single pre-tension valve assembly in manifold

Flow meter

Electric motor unidirectional variable speed

Rev.1 02/2009

110

PTH50 Series

HYDRAULIC SCHEMATIC Hydraulic Symbols Icon

Meaning

Icon

Meaning

Valve block with 3 operating units

Proportional solenoid

Shuttle valve

Dual solenoid

Relief valve, fixed setting

Hydraulic pilot operated solenoid valve

Velocity fuse

Hydraulic pilot operated hydraulic valve

Pressure-compensated flow control with reverseflow bypass; fixed.

Manual actuator

Pressure-compensated flow control, fixed

Single-acting cylinder, with cushion

Pilot check valve(pilot to open)

Single-acting cylinder ram type

Manual lever actuator

Single-acting cylinder with spring returned (rod end vented)

PTH50 Series

Rev.1 02/2009

111

HYDRAULIC SCHEMATIC Hydraulic Symbols Icon

Rev.1 02/2009

112

Meaning

Icon

Meaning

Double-acting cylinder; equal area

Thermometer

Double-acting cylinder; unequal area

Pressure gauge

Pressure switch

Hydraulic motor, bidirectional

PTH50 Series

HYDRAULIC SCHEMATIC PTH50 PS Hydraulic Diagram PTH50 PS Hydraulic Diagram

Hydraulic aggregate (electric)

1

2 3

4

Hydraulic unit (mechanical)

Fig. 58 PTH50 PS Hydraulic Diagram

PTH50 Series

113

HYDRAULIC SCHEMATIC PTH50 PS Hydraulic Diagram 1

Relief valve

2

Cylinder

3

Lower valve

4

Relief valve

Note: The term "hydraulic unit" designates the hydraulic and mechanical section with the pump piston and lift cylinder. The term "hydraulic aggregate" designates the electro-mechanical section with the pump motor, hydraulic pump and hydraulic reservoir.

PTH50 Series

114

PTH50 SERIES PARTS CATALOG

P Order Number: 812572-006 Revision: A • Printed in Germany

This master manual is subject to continual updates.

It is intended solely for companies authorised by Crown.

The distribution of its content or copies thereof to third parties is prohibited.

Crown Gabelstapler GmbH & Co. KG - European Headquarters Moosacher Str. 52 80809 Munich Germany Tel: +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 2010 Crown Equipment Corporation

INTRODUCTION

117

Notes:

118

INTRODUCTION Important Customer Information

Important Customer Information

Maintenance, repairs and training

This parts catalog applies to the following models: •

PTH50

•

PTH50 WS

•

PTH50 GLV

•

PTH50 S

•

PTH50 PS

To maintain the safety and functionality of the truck, maintenance and repair work must only be performed by service engineers who have been authorised by Crown. Please contact Crown if you wish to have your engineers trained.

Details of routine inspection and maintenance work to be performed by the customer can be found in the Maintenance and Safety Inspection chapter of the operator manual.

Ordering spare parts

Manual structure

Always quote the following numbers when ordering spare parts:

The manual is divided into the following sections:

•

Specification number

•

Model number

•

Serial number

Section

Contents

ITD

Introduction

These numbers can be found on the truck data plate.

For details of your truck's technical specifications refer to the Technical Specifications chapter in the operator manual.

2

Hydraulic System

4

Electrical System

5

Brake System

Further information on your truck can be obtained from your Crown dealer or the following address:

7

Lifting Mechanism

10

Glossary

Abbreviations used

Crown Gabelstapler GmbH & Co. KG Moosacher Str. 52 D-80809 Munich Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 or 133

Abbreviation

Description

AR (As Required)

Indicates an unspecified quantity; to be ordered as required.

F/C (Freezer/Corrosion)

Cold store truck with extra corrosion protection

NA (Not Available)

Not available.

Truck modifications WARNING Fatal accidents can be caused by modifying the original condition of the truck.

Changes to the original condition of the truck when delivered can lead to fatal accidents.  Any necessary changes to the original condition of the truck must be checked and approved in writing

by Crown Gabelstapler GmbH & Co. KG prior to being made.

PTH50 Series

119

Notes:

120

HYDRAULIC SYSTEM

121

HYDRAULIC SYSTEM Hydraulic Unit PTH50 Hydraulic Unit PTH50

Fig. 59 PTH50 Series

122

HYDRAULIC SYSTEM Hydraulic Unit PTH50 ITEM

PART NUMBER

NAME

QUANTITY

0 . . . . . . . 816814-001 . . . . . . . Hydraulic unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819610 . . . . . . . . . . . Hydraulic unit, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 . . . . . . . . . . 046234. . . . . . . . . . . . Piston ram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . . . . 054001-008 . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . . . . 050012-025 . . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050012-060 . . . . . . . . Retaining ring, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . . . . 041165 . . . . . . . . . . . . Cylinder tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . . . . 054015-001 . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . . . . 041181 . . . . . . . . . . . . Drain plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045861. . . . . . . . . . . . Drain plug, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . . . . 050011-019 . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . . . . 050000-070 . . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050000-079 . . . . . . . . Dowel pin, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . . . . 816818. . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819187. . . . . . . . . . . . Axle (galvanised). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . . . . 814119-001 . . . . . . . . Pump housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

816844-001 . . . . . . . . Pump housing, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . . . . 818252. . . . . . . . . . . . Valve cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819180. . . . . . . . . . . . Seal kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . . . . 818260. . . . . . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . . . . 818262. . . . . . . . . . . . Deflector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . . . . 816815. . . . . . . . . . . . Piston boss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819608. . . . . . . . . . . . Piston boss, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . . . . 054015-005 . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . . . . 054001-009 . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . . . . 044570. . . . . . . . . . . . Spring ....................................................

819189. . . . . . . . . . . . Spring, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . . . . 044452. . . . . . . . . . . . Washer ...................................................

819607. . . . . . . . . . . . Washer, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . . . . 816816. . . . . . . . . . . . Pump piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . . . . 050012-033 . . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050012-058 . . . . . . . . Retaining ring, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . . . . 818261. . . . . . . . . . . . Deflector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 . . . . . . . . . . 818263. . . . . . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . . . . 816819. . . . . . . . . . . . Control piston ..............................................

819186. . . . . . . . . . . . Control piston, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 . . . . . . . . . . 044456. . . . . . . . . . . . Spring ....................................................

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

819934 . . . . . . . . . . . Seal Kit (including 2, 5, 7, 12, to 13, 15, 18, 21, 22). . . . . . . . . . . . . . . . . . .

1

Always specify the model and serial numbers.

PTH50 Series

123

HYDRAULIC SYSTEM PTH50 PS Hydraulic Unit PTH50 PS Hydraulic Unit

See page 128 See page 126

Fig. 60 PTH50 Series

124

HYDRAULIC SYSTEM PTH50 PS Hydraulic Unit ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 046028 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 050003-040 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 054174-001 . . . . . . . Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 045976-002 . . . . . . . Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 050071-012 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050050-005 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050003-002 . . . . . . . Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 046032 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 045976-001 . . . . . . . Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 064485 . . . . . . . . . . . Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 3 1 5 2 1 1 1 1

Always specify the model and serial numbers.

PTH50 Series

125

HYDRAULIC SYSTEM Pump motor and pump PTH50 PS Pump motor and pump PTH50 PS

Fig. 61 PTH50 Series

126

HYDRAULIC SYSTEM Pump motor and pump PTH50 PS ITEM

PART NUMBER

NAME

QUANTITY

0 . . . . . . . 045975 . . . . . . . . . . . Pump motor and pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 . . . . . . . . . . NA . . . . . . . . . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . . . . NA . . . . . . . . . . . . . . . Washer ...................................................

3 . . . . . . . . . . NA . . . . . . . . . . . . . . . Expansion plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . . . . NA . . . . . . . . . . . . . . . Circlip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . . . . NA . . . . . . . . . . . . . . . Bearing cover ..............................................

6 . . . . . . . . . . NA . . . . . . . . . . . . . . . Insulating protective cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . . . . NA . . . . . . . . . . . . . . . Carbon brush bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . . . . 046014. . . . . . . . . . . . Carbon brush set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . . . . NA . . . . . . . . . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . . . . NA . . . . . . . . . . . . . . . Armature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . . . . NA . . . . . . . . . . . . . . . Motor housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . . . . NA . . . . . . . . . . . . . . . Drive bearing cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . . . . 805144. . . . . . . . . . . . Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . . . . 046008. . . . . . . . . . . . Pump connector plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . . . . 046009. . . . . . . . . . . . Pressure relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . . . . 046010. . . . . . . . . . . . Breather. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . . . . 805151. . . . . . . . . . . . Pressure filter ..............................................

18 . . . . . . . . . . 805152. . . . . . . . . . . . Check valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . . . . 805154. . . . . . . . . . . . Return line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . . . . 046012. . . . . . . . . . . . Suction line (including 21). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . . . . . . .046017 . . . . . . . . . . . Nozzle filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 . . . . . . . . . . 046011 . . . . . . . . . . . . Return line (including 21). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . . . . 805157. . . . . . . . . . . . Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 4 4 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 2 1 1

046013. . . . . . . . . . . . Pump motor (including 1 to 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046015. . . . . . . . . . . . Screw set (including 1 to 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046016. . . . . . . . . . . . Bearing cover (including 3, 4, 6 to 8). . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1

Always specify the model and serial numbers.

PTH50 Series

127

HYDRAULIC SYSTEM PTH50 PS Hydraulic Unit, Part 1 / 2 PTH50 PS Hydraulic Unit, Part 1 / 2

Fig. 62 PTH50 Series

128

HYDRAULIC SYSTEM PTH50 PS Hydraulic Unit, Part 1 / 2 ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 141404-002 . . . . . . . Pump housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 050000-015 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 050012-035 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 045702 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 054153-003 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 045700 . . . . . . . . . . . Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 055001-002 . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 816912 . . . . . . . . . . . O Ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 816913 . . . . . . . . . . . Backring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . 816917 . . . . . . . . . . . Piston boss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 054015-005 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . 054001-009 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 050012-033 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . 816919 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . 816911 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . 819183 . . . . . . . . . . . Pump piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 141399 . . . . . . . . . . . Cylinder outer tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 064260-010 . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . 816817 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . 050000-070 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . 816818 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 . . . . . . . 142545 . . . . . . . . . . . Overload valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . 818252 . . . . . . . . . . . Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819180 . . . . . . . . . . . Seal kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 . . . . . . . 041181 . . . . . . . . . . . Drain plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . 050011-019. . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 . . . . . . . 044456 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 . . . . . . . 816819 . . . . . . . . . . . Control piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 . . . . . . . 818263 . . . . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 . . . . . . . 818261 . . . . . . . . . . . Deflector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 . . . . . . . 046122 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 2

Always specify the model and serial numbers.

PTH50 Series

129

HYDRAULIC SYSTEM PTH50 PS Hydraulic Unit, Part 2 / 2 PTH50 PS Hydraulic Unit, Part 2 / 2

See page 128

Fig. 63 PTH50 Series

130

HYDRAULIC SYSTEM PTH50 PS Hydraulic Unit, Part 2 / 2 ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 054015-001 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 064260-007 . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 141398 . . . . . . . . . . . Cylinder nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 054001-008 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 046186 . . . . . . . . . . . Piston ram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 064260-010 . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 064074-047 . . . . . . . Backring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 064260-009 . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 050012-025 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . 141403 . . . . . . . . . . . Cylinder tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 050005-010 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 2 2 1 1 3

Always specify the model and serial numbers.

PTH50 Series

131

HYDRAULIC SYSTEM PTH50 S Hydraulic Unit, Version 1, Part 1 / 2 PTH50 S Hydraulic Unit, Version 1, Part 1 / 2

Fig. 64 PTH50 Series

132

HYDRAULIC SYSTEM PTH50 S Hydraulic Unit, Version 1, Part 1 / 2 ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 141404-001 . . . . . . . Pump housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 050000-015 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 050012-035 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 045702 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 054153-003 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 045700 . . . . . . . . . . . Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 055001-002 . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 816912 . . . . . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 816913 . . . . . . . . . . . Backring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . 816917 . . . . . . . . . . . Piston boss. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 054015-005 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . 054001-009 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 050012-033 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . 816919 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . 816911 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . 819183 . . . . . . . . . . . Pump piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 045850 . . . . . . . . . . . Filler plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 141400-001 . . . . . . . Cylinder outer tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . 064260-010 . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . 816817 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . 050000-070 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 . . . . . . . 816818 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . 142545 . . . . . . . . . . . Relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 . . . . . . . 818252 . . . . . . . . . . . Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819180 . . . . . . . . . . . Seal set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . 041181 . . . . . . . . . . . Drain plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 . . . . . . . 050011-019. . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 . . . . . . . 044456 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 . . . . . . . 816819 . . . . . . . . . . . Control piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 . . . . . . . 818263 . . . . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 . . . . . . . 818261 . . . . . . . . . . . Deflector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 . . . . . . . 046122 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 2

Always specify the model and serial numbers.

PTH50 Series

133

HYDRAULIC SYSTEM PTH50 S Hydraulic Unit, Version 1, Part 2 / 2 PTH50 S Hydraulic Unit, Version 1, Part 2 / 2

See page 132

Fig. 65 PTH50 Series

134

HYDRAULIC SYSTEM PTH50 S Hydraulic Unit, Version 1, Part 2 / 2 ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 054015-001 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 064260-007 . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 141398 . . . . . . . . . . . Cylinder nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 054001-008 . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 046186 . . . . . . . . . . . Piston ram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 064260-010 . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 064074-047 . . . . . . . Backring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 064260-009 . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 050012-025 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . 141403 . . . . . . . . . . . Cylinder tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 050005-010 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 2 2 1 1 3

Always specify the model and serial numbers.

PTH50 Series

135

HYDRAULIC SYSTEM PTH50 S Hydraulic Unit, Version 2 PTH50 S Hydraulic Unit, Version 2

Fig. 66 PTH50 Series

136

HYDRAULIC SYSTEM PTH50 S Hydraulic Unit, Version 2 ITEM

PART NUMBER

NAME

QUANTITY

0 . . . . . . . 045762 . . . . . . . . . . . Hydraulic unit (complete / excl. 10). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 . . . . . . . . . . 045791. . . . . . . . . . . . Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 . . . . . . . . . . 045850. . . . . . . . . . . . Filler plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 . . . . . . . . . . 041166 . . . . . . . . . . . . Spacer bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4 . . . . . . . . . . 054015-001 . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 . . . . . . . . . . 041165 . . . . . . . . . . . . Guide bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6 . . . . . . . . . . 050012-025 . . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7 . . . . . . . . . . 054001-008 . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8 . . . . . . . . . . 041254. . . . . . . . . . . . Magnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9 . . . . . . . . . . 045769. . . . . . . . . . . . Piston ram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 10 . . . . . . . 055001-010 . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 11 . . . . . . . . . . 050012-033 . . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 12 . . . . . . . . . . 044452. . . . . . . . . . . . Washer ................................................... 1 13 . . . . . . . . . . 044570. . . . . . . . . . . . Spring .................................................... 1 14 . . . . . . . . . . 054015-005 . . . . . . . . Conical nipple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 15 . . . . . . . . . . 045705. . . . . . . . . . . . Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 16 . . . . . . . . . . 064074-005 . . . . . . . . Backring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 17 . . . . . . . . . . 054002-012 . . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 18 . . . . . . . . . . 045704. . . . . . . . . . . . Piston ram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 19 . . . . . . . . . . 802313. . . . . . . . . . . . Spring .................................................... 1 20 . . . . . . . . . . 055001-002 . . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 21 . . . . . . . . . . 045700. . . . . . . . . . . . Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 22 . . . . . . . . . . 054153-003 . . . . . . . . Conical nipple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 23 . . . . . . . . . . 045702. . . . . . . . . . . . Conical nipple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 24 . . . . . . . . . . 050012-035 . . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 25 . . . . . . . . . . 045703. . . . . . . . . . . . Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 26 . . . . . . . . . . 054002-033 . . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 27 . . . . . . . . . . 054006-001 . . . . . . . . Backring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 28 . . . . . . . . . . 050012-064 . . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 29 . . . . . . . . . . 050012-026 . . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 30 . . . . . . . . . . 054002-024 . . . . . . . . O ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 31 . . . . . . . . . . 044455. . . . . . . . . . . . Control piston .............................................. 1 32 . . . . . . . . . . 044456. . . . . . . . . . . . Spring .................................................... 1 33 . . . . . . . . . . 055001-007 . . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 34 . . . . . . . . . . 041286. . . . . . . . . . . . Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 35 . . . . . . . . . . 050011-010 . . . . . . . . Washer ................................................... 1 36 . . . . . . . . . . 041289. . . . . . . . . . . . Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 37 . . . . . . . . . . 041288. . . . . . . . . . . . Spring .................................................... 1 38 . . . . . . . . . . 050011-020 . . . . . . . . Washer ................................................... 2 39 . . . . . . . . . . 041301. . . . . . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 40 . . . . . . . . . . 044724. . . . . . . . . . . . Setscrew. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 41 . . . . . . . . . . 044722. . . . . . . . . . . . Carrier (complete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 044723 . . . . . . . . . . . Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 055016-001 . . . . . . . Spring washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 050012-044 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Always specify the model and serial numbers.

PTH50 Series

137

HYDRAULIC SYSTEM PTH50 S Hydraulic Unit, Version 2 PTH50 S Hydraulic Unit, Version 2

Fig. 67 PTH50 Series

138

HYDRAULIC SYSTEM PTH50 S Hydraulic Unit, Version 2 ITEM

PART NUMBER

NAME

QUANTITY

42 . . . . . . . . . . 055001-001 . . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 . . . . . . . . . . 044457. . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 . . . . . . . . . . 050000-070 . . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 . . . . . . . . . . 054001-009 . . . . . . . . Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1

045674. . . . . . . . . . . . High speed lift (including 11 - 28) ...............................

1

Always specify the model and serial numbers.

PTH50 Series

139

Notes:

140

ELECTRICAL SYSTEM

141

ELECTRICAL SYSTEM PTH50 WS Electrical System PTH50 WS Electrical System

See page 156

Fig. 68 PTH 50 Series

142

ELECTRICAL SYSTEM PTH50 WS Electrical System ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 815740 . . . . . . . . . . . Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 815738 . . . . . . . . . . . Indicator circuit board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

815739 . . . . . . . . . . . LCD module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 815741 . . . . . . . . . . . PC board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 815737 . . . . . . . . . . . Adapter - bracket (indicator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 815736 . . . . . . . . . . . Bracket (indicator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 815744 . . . . . . . . . . . Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

815729 . . . . . . . . . . . Cover plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

815730 . . . . . . . . . . . Cover plate (printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 815746 . . . . . . . . . . . Printer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 815747 . . . . . . . . . . . Printer cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 815748 . . . . . . . . . . . Paper roll ....................................................

10 . . . . . . . 815726 . . . . . . . . . . . Charger (220 V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

815728 . . . . . . . . . . . Charger (110 V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . . . . 815745. . . . . . . . . . . . Retaining cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . . . . 046100. . . . . . . . . . . . Fuse (2 A). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 815727 . . . . . . . . . . . Battery (including 11 and 12). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . . . . . . . . . . . . . . . . . . Load cell. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . . . . . . . . . . . . . . . . . . Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . 815731 . . . . . . . . . . . Adjusting board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 815733 . . . . . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 815734 . . . . . . . . . . . Retaining spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . 815735 . . . . . . . . . . . Battery housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 4 1 2 2 1

815742 . . . . . . . . . . . Display unit (including 1 and 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

815743 . . . . . . . . . . . Display unit (including 1 and 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1

Always specify the model and serial numbers.

PTH 50 Series

143

ELECTRICAL SYSTEM PTH50 PS Electrical System PTH50 PS Electrical System

Fig. 69 PTH 50 Series

144

ELECTRICAL SYSTEM PTH50 PS Electrical System ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 045993-004 . . . . . . . Rubber socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 045993-003 . . . . . . . Rubber socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 045964 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 050003-002 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 055005-003 . . . . . . . Rubber socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 045969-002 . . . . . . . Rubber socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 046039 . . . . . . . . . . . Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 069346 . . . . . . . . . . . Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 045972 . . . . . . . . . . . Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . 045988 . . . . . . . . . . . Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 050008-005 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . 050071-012 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 804801 . . . . . . . . . . . Insulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . 050006-023 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050009-013 . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . 045984 . . . . . . . . . . . Bus bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . 045982 . . . . . . . . . . . Switch actuator (Emergency Disconnect switch). . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 045977 . . . . . . . . . . . Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 061003-003 . . . . . . . Clamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . 045985-002 . . . . . . . Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . 045986 . . . . . . . . . . . Rotary fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . 045987 . . . . . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 . . . . . . . 805752 . . . . . . . . . . . Fuse holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . 050004-024 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 . . . . . . . 045981 . . . . . . . . . . . Fuse FU2 (5 A / 32 V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . 050004-012 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 . . . . . . . 046250 . . . . . . . . . . . Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 . . . . . . . 050009-013 . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 . . . . . . . 050006-023 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 . . . . . . . 818257 . . . . . . . . . . . Battery ......................................................

30 . . . . . . . 050004-010 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 . . . . . . . 050010-007 . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 . . . . . . . 050009-003 . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 . . . . . . . 045978 . . . . . . . . . . . Fuse holder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 . . . . . . . 045979 . . . . . . . . . . . Fuse FU1 (80 A / 32 V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 . . . . . . . 050008-010 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 . . . . . . . 050006-013 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 . . . . . . . 045993-002 . . . . . . . Rubber socket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 . . . . . . . 814533 . . . . . . . . . . . Mains connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 . . . . . . . 814589 . . . . . . . . . . . Charger (230 VAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

814717 . . . . . . . . . . . Charger (110 V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 . . . . . . . 046019 . . . . . . . . . . . Fuse FU3 (15 A / 32 V). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 4 1 2 1 1 1 2 2 2 1 2 2 1 1 1 1 1 1 1 1 2 1 1 1 2 2 1 2 2 2 1 1 1 1 1 1 1 1 1

Always specify the model and serial numbers.

PTH 50 Series

145

Notes:

146

BRAKE SYSTEM

147

BRAKE SYSTEM Parking Brake Parking Brake

See page 152

See page 152

See page 152 See page 152

Fig. 70 PTH 50 Series

148

BRAKE SYSTEM Parking Brake ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 050000-012 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 041382 . . . . . . . . . . . Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 041380 . . . . . . . . . . . Catch .......................................................

4 . . . . . . . 050012-028 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 041375 . . . . . . . . . . . Brake lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 041378 . . . . . . . . . . . Hand grip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 041381 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 041384 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 041383 . . . . . . . . . . . Locking button ................................................

10 . . . . . . . 050000-019 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 055005-003 . . . . . . . Grommet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . 045093 . . . . . . . . . . . Brake shoe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 044690-001 . . . . . . . Brake plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . 045094 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . 050000-007 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . 050008-015 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 044662 . . . . . . . . . . . Pivot point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 044661 . . . . . . . . . . . Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . 044690-002 . . . . . . . Brake plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . 041379 . . . . . . . . . . . Bowden cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1 2 2 2 1 4 2 2 1 1 1 1

044659-001 . . . . . . . Brake (including 12 - 14). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044659-002 . . . . . . . Brake (including 12, 13 and 19). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1

Always specify the model and serial numbers.

PTH 50 Series

149

Notes:

150

LIFTING MECHANISM

151

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 1 / 2 PTH50 Lifting Mechanism, Part 1 / 2

Fig. 71 PTH 50 Series

152

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 1 / 2 ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 818104 . . . . . . . . . . . Control handle ................................................

818277 . . . . . . . . . . . Control handle, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

816105 . . . . . . . . . . . Control handle (with parking brake). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 050000-012 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050000-082 . . . . . . . Dowel pin, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 041292 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 055001-007 . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 044600 . . . . . . . . . . . Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 055001-010 . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 816817 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819605 . . . . . . . . . . . Axle, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 050000-015 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050000-083 . . . . . . . Dowel pin, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic unit (see page 122). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . 055018-001 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 819174 . . . . . . . . . . . Cross member. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046130 . . . . . . . . . . . Cross member, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . 054011-001. . . . . . . . Grease nipple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 050012-024 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050012-062 . . . . . . . Retaining ring, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . 050000-012 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050000-082 . . . . . . . Dowel pin, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . 050006-053 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . 044499 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045635 . . . . . . . . . . . Axle, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 050008-049 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 055002-025 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

055002-023 . . . . . . . Ball bearing, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

065081-020 . . . . . . . Ball bearing (with parking brake). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . 818270 . . . . . . . . . . . Steer wheels (polyamide / orange). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

818271 . . . . . . . . . . . Steer wheels (nylon / orange). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

818272 . . . . . . . . . . . Steer wheels (rubber / orange). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045546 . . . . . . . . . . . Steer wheels; complete (with parking brake). . . . . . . . . . . . . . . . . . . . . . . .

044997. . . . . . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . 050012-021 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050012-053 . . . . . . . Retaining ring, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . 818273 . . . . . . . . . . . Fender ......................................................

22 . . . . . . . 050005-002 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050005-056 . . . . . . . Screw, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . 044535 . . . . . . . . . . . Chain mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 . . . . . . . 046128 . . . . . . . . . . . Chain (complete) ..............................................

045630 . . . . . . . . . . . Chain, PTH50 GLV (complete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044535. . . . . . . . . . . . Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045631. . . . . . . . . . . . Chain, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046127. . . . . . . . . . . . Chain lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045632. . . . . . . . . . . . Chain lock, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . 044580 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 . . . . . . . 079918-001 . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045634 . . . . . . . . . . . Spring, PTH50 GLV ............................................

1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 4 4 4 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 2 1 1

Always specify the model and serial numbers.

PTH 50 Series

153

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 2 / 2 PTH50 Lifting Mechanism, Part 2 / 2

Fig. 72 PTH 50 Series

154

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 2 / 2 ITEM

PART NUMBER

NAME

QUANTITY

27 . . . . . . . 044579 . . . . . . . . . . . Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 . . . . . . . 044527 . . . . . . . . . . . Tie rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045588 . . . . . . . . . . . Tie rod, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 . . . . . . . 044531 . . . . . . . . . . . Adjusting pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 . . . . . . . 055084-003 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 . . . . . . . 046236 . . . . . . . . . . . Distance roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045590 . . . . . . . . . . . Distance roll, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 . . . . . . . 055084-001 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 . . . . . . . 819182 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045587 . . . . . . . . . . . Axle, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 2 1 1 2 1 1

818275-101 . . . . . . . Steer wheels, polyamide / orange (including 18 and 19). . . . . . . . . . . . . . .

818275-102 . . . . . . . Steer wheels, nylon / orange (including 18 and 19). . . . . . . . . . . . . . . . . . .

818275-103 . . . . . . . Steer wheels, rubber / orange (including 18 and 19). . . . . . . . . . . . . . . . . .

818275-201 . . . . . . . Steer wheels, PTH50 GLV (including 18 and 19). . . . . . . . . . . . . . . . . . . . .

044586 . . . . . . . . . . . Insert (including 25 and 27). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1

Always specify the model and serial numbers.

PTH 50 Series

155

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 2 / 2 PTH50 Lifting Mechanism, Part 2 / 2

Fig. 73 PTH 50 Series

156

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 2 / 2 ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 041201 . . . . . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 045671 . . . . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045592 . . . . . . . . . . . Bolt, PTH50 GLV ..............................................

3 . . . . . . . 055084-002 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 050000-007 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050000-083 . . . . . . . Dowel pin, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 045669 . . . . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045597 . . . . . . . . . . . Bolt, PTH50 GLV ..............................................

6 . . . . . . . 050000-015 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050000-085 . . . . . . . Dowel pin, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . . . . . . . . . . . . . . . . . . Fork carriage (see table on page 158). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045608-001-05 . . . . . Fork carriage, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

815732 . . . . . . . . . . . Fork carriage, PTH50 WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

815744 . . . . . . . . . . . Console, PTH50 WS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 050007-023 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 044461 . . . . . . . . . . . Roller .......................................................

10 . . . . . . . 050008-025 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 055002-025 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

055002-023 . . . . . . . Ball bearing, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . 044507 . . . . . . . . . . . Load wheel (polyamide). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044508 . . . . . . . . . . . Load wheel (nylon). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 045676 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045598 . . . . . . . . . . . Axle, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . 050000-007 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050000-083 . . . . . . . Dowel pin, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . 044777 . . . . . . . . . . . Roller .......................................................

16 . . . . . . . 042053-012 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 041139 . . . . . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 044504 . . . . . . . . . . . Riser (RH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045654 . . . . . . . . . . . Riser RH, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044505 . . . . . . . . . . . Riser (LH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045655 . . . . . . . . . . . Riser LH, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . . . . . . . . . . . . . . . . . . Pushrod (see page 158). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819918-005 . . . . . . . Pushrod, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

818274-005 . . . . . . . Pushrod (with parking brake). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . 042053-011. . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . 045670 . . . . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045593 . . . . . . . . . . . Bolt, PTH50 GLV ..............................................

22 . . . . . . . 050079-003 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050000-081 . . . . . . . Dowel pin, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . 050012-021 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

050012-053 . . . . . . . Retaining ring, PTH50 GLV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 . . . . . . . 815749 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . . . . . . . . . . . . . . . . . . Riser (see table on page 160). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

819933 . . . . . . . . . . . Riser, PTH50 GLV .............................................

816962 . . . . . . . . . . . Riser (with parking brake). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 2 2 2 2 2 2 2 1 1 1 1 1 1 2 2 2 4 4 2 2 2 2 4 4 4 4 4 2 2 2 2 2 2 2 4 2 2 2 2 2 2 4 1 1 1

044506-101 . . . . . . . Load wheel, polyamide (including 11 and 12). . . . . . . . . . . . . . . . . . . . . . . .

044506-102 . . . . . . . Load wheel, nylon (including 11 and 12) ............................

044506-201 . . . . . . . Load wheel, PTH50 GLV (including 11 and 12). . . . . . . . . . . . . . . . . . . . . .

2 2 2

Always specify the model and serial numbers.

PTH 50 Series

157

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 2 / 2 PTH50 Lifting Mechanism, Part 2 / 2

Fig. 74 PTH 50 Series

158

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 2 / 2

Fork Carriage, Item 7 Fork Straddle

Fork Length 800 mm

900 mm

990 mm

1050 mm

1150 mm

400 mm

816572-001-01

816572-001-02

816572-001-03

816572-001-04

816572-001-05

450 mm

816573-001-01

816573-001-02

816573-001-03

816573-001-04

816573-001-05

520 mm

816574-001-01

816574-001-02

816574-001-03

816574-001-04

816574-001-05

685 mm

816575-001-01

816575-001-02

816575-001-03

816575-001-04

816575-001-05

Fork Carriage, Item 7 Fork Straddle

Fork Length 1200 mm

1350 mm

1500 mm

1800 mm

2000 mm

400 mm

816572-001-06

450 mm

816573-001-06

520 mm

816574-001-06

816574-001-07

816574-001-08

816574-001-09

816574-001-10

685 mm

816575-001-06

816575-001-07

816575-001-08

816575-001-09

816575-001-10

Pushrod Items 19 and 20 (complete)

Item 19

Fork Length

818259-001

818274-001

800 mm

818259-002

818274-002

900 mm

818259-003

818274-003

990 mm

818259-004

818274-004

1050 mm

818259-005

818274-005

1150 mm

818259-006

818274-006

1200 mm

818278-007

818258-007

1350 mm

818278-008

818258-008

1500 mm

818278-009

818258-009

1800 mm

818278-010

818258-010

2000 mm

PTH 50 Series

159

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 2 / 2 PTH50 Lifting Mechanism, Part 2 / 2

Fig. 75 PTH 50 Series

160

LIFTING MECHANISM PTH50 Lifting Mechanism, Part 2 / 2

Riser Fork Straddle

Item 25

400 mm

818250

450 mm

818251

520 mm

816962

685 mm

818255

PTH 50 Series

161

LIFTING MECHANISM Tandem Load Wheel PTH50 Tandem Load Wheel PTH50

Fig. 76 PTH 50 Series

162

LIFTING MECHANISM Tandem Load Wheel PTH50 ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 042053-012 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 2 . . . . . . . 044643 . . . . . . . . . . . Riser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3 . . . . . . . 041139 . . . . . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 . . . . . . . 044642 . . . . . . . . . . . Riser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5 . . . . . . . 045678 . . . . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6 . . . . . . . 055084-003 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7 . . . . . . . 046062 . . . . . . . . . . . Shim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8 . . . . . . . 055002-025 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 9 . . . . . . . 044512 . . . . . . . . . . . Load wheel (polyamide). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 044513 . . . . . . . . . . . Load wheel (nylon). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 10 . . . . . . . 044514 . . . . . . . . . . . Compensating plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 11 . . . . . . . 050000-014 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 12 . . . . . . . 046064 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

044645 . . . . . . . . . . . Riser (including 1, 2, 3 and 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044644 . . . . . . . . . . . Riser (including 1, 3, 4 and 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044511-101. . . . . . . . Load wheel, polyamide (including 8 and 9) ..........................

044511-102. . . . . . . . Load wheel, nylon (including 8 and 9). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 2 4 4

Always specify the model and serial numbers.

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1 . . . . . . . 046170 . . . . . . . . . . . Control handle and decal (complete). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

818106. . . . . . . . . . . . Control handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

869290. . . . . . . . . . . . Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 050000-012 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 055001-007 . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 041292 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 044600 . . . . . . . . . . . Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 046235 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 055084-001 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 046236 . . . . . . . . . . . Distance roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 055084-003 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . 044531 . . . . . . . . . . . Adjusting pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 044527 . . . . . . . . . . . Tie rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . 044579 . . . . . . . . . . . Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 044580 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . 079918-001 . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . 046128 . . . . . . . . . . . Chain (complete) ..............................................

044533. . . . . . . . . . . . Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046127. . . . . . . . . . . . Chain lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . 044535 . . . . . . . . . . . Chain mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 050005-002 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 045931 . . . . . . . . . . . Fork carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . 050000-015 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . 045797 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046238 . . . . . . . . . . . Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . 050000-014 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic unit (see page 124). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . 055001-010 . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 . . . . . . . 055018-001 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . 045934 . . . . . . . . . . . Battery compartment ...........................................

26 . . . . . . . 816817 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 . . . . . . . 042053-011. . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 . . . . . . . 054011-001. . . . . . . . Grease nipple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 . . . . . . . 055084-011. . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 . . . . . . . 050012-024 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 . . . . . . . 045786 . . . . . . . . . . . Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 . . . . . . . 050003-035 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33 . . . . . . . 055002-004 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 . . . . . . . 044496 . . . . . . . . . . . Steer wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 . . . . . . . 050012-021 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 . . . . . . . 044437 . . . . . . . . . . . Fender ......................................................

37 . . . . . . . 045803 . . . . . . . . . . . Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 . . . . . . . 045798 . . . . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 . . . . . . . 045800 . . . . . . . . . . . Stabiliser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 . . . . . . . 060005-015 . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 . . . . . . . 050008-048 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 . . . . . . . 055002-024 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 . . . . . . . 044516 . . . . . . . . . . . Shim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 . . . . . . . 055002-004 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 2 1 1 1 2 1 2 1 1 1 2 1 1 1 1 1 1 1 4 2 2 2 1 1 1 1 1 6 2 1 1 1 1 4 2 2 2 1 2 2 2 2 4 8 4

Always specify the model and serial numbers.

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45 . . . . . . . 044512 . . . . . . . . . . . Load wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 . . . . . . . 045809 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47 . . . . . . . 050000-016 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 . . . . . . . 045802 . . . . . . . . . . . Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 . . . . . . . 055084-002 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 . . . . . . . 045801 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51 . . . . . . . 050003-040 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52 . . . . . . . 045780 . . . . . . . . . . . Lift frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 2 2 1 2 2 2 1

046169 . . . . . . . . . . . Control handle (including 1 - 17). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046129 . . . . . . . . . . . Tie rod (including 11, 15 and 16) ..................................

044586 . . . . . . . . . . . Insert (including 12 and 13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045933 . . . . . . . . . . . Battery compartment (including 25, 27 - 29). . . . . . . . . . . . . . . . . . . . . . . . .

045807 . . . . . . . . . . . Arm (including 27, 37, 43 - 47 and 49). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045806 . . . . . . . . . . . Arm (including 27, 43 - 49). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044495-001 . . . . . . . Steer wheels (including 33 and 34). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045808 . . . . . . . . . . . Lift frame (including 39 - 42 and 52). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044511-101. . . . . . . . Load wheel (including 44 and 45). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1 1

Always specify the model and serial numbers.

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Fig. 79 PTH 50 Series

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PART NUMBER

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1 . . . . . . . 143722 . . . . . . . . . . . Control handle ................................................

869290 . . . . . . . . . . . Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 050000-012 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 . . . . . . . 055001-007 . . . . . . . Ball. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . 041292 . . . . . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 . . . . . . . 044600 . . . . . . . . . . . Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 819182 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 . . . . . . . 055084-001 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 . . . . . . . 046236 . . . . . . . . . . . Distance roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 . . . . . . . 055084-003 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 . . . . . . . 044531 . . . . . . . . . . . Adjusting pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11 . . . . . . . 044527 . . . . . . . . . . . Tie rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 . . . . . . . 044579 . . . . . . . . . . . Insert. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13 . . . . . . . 044580 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 . . . . . . . 079918-001 . . . . . . . Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15 . . . . . . . 046128 . . . . . . . . . . . Chain (complete) ..............................................

044533. . . . . . . . . . . . Chain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046127. . . . . . . . . . . . Chain lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16 . . . . . . . 044535 . . . . . . . . . . . Chain mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 . . . . . . . 050005-002 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 . . . . . . . 045785 . . . . . . . . . . . Fork carriage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19 . . . . . . . 050000-015 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic unit (see page 136). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 . . . . . . . 046230 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 . . . . . . . 045672 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 . . . . . . . 055018-001 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24 . . . . . . . 045766 . . . . . . . . . . . Cross bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 . . . . . . . 054011-001. . . . . . . . Grease nipple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26 . . . . . . . 050012-024 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27 . . . . . . . 045786 . . . . . . . . . . . Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 . . . . . . . 050003-035 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 . . . . . . . 044496 . . . . . . . . . . . Steer wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 . . . . . . . 055002-004 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31 . . . . . . . 050012-021 . . . . . . . Retaining ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 . . . . . . . 044437 . . . . . . . . . . . Fender ......................................................

33 . . . . . . . 045803 . . . . . . . . . . . Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 . . . . . . . 045802 . . . . . . . . . . . Arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 . . . . . . . 045780 . . . . . . . . . . . Lift frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36 . . . . . . . 045798 . . . . . . . . . . . Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37 . . . . . . . 045800 . . . . . . . . . . . Stabiliser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38 . . . . . . . 050008-048 . . . . . . . Nut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

060005-015 . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39 . . . . . . . 055002-024 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40 . . . . . . . 042053-011. . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41 . . . . . . . 055084-002 . . . . . . . Bushing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42 . . . . . . . 045801 . . . . . . . . . . . Washer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43 . . . . . . . 050003-040 . . . . . . . Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44 . . . . . . . 045809 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 . . . . . . . 050000-016 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46 . . . . . . . 044516 . . . . . . . . . . . Shim. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 2 1 1 1 2 1 2 1 1 1 2 1 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 2 4 2 2 1 1 1 2 2 2 2 4 6 2 2 2 2 2 8

Always specify the model and serial numbers.

PTH 50 Series

169

LIFTING MECHANISM PTH50 S Lifting Mechanism PTH50 S Lifting Mechanism

Fig. 80 PTH 50 Series

170

LIFTING MECHANISM PTH50 S Lifting Mechanism ITEM

PART NUMBER

NAME

QUANTITY

47 . . . . . . . 055002-004 . . . . . . . Ball bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48 . . . . . . . 044512 . . . . . . . . . . . Load wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49 . . . . . . . 045797 . . . . . . . . . . . Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

046238 . . . . . . . . . . . Spacer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50 . . . . . . . 050000-014 . . . . . . . Dowel pin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 2 2 2 2

143724-001 . . . . . . . Control handle (including 1 - 17). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044586 . . . . . . . . . . . Insert (including 12 and 13). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045807 . . . . . . . . . . . Arm (including 33, 40, 41, 44 - 48). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045806 . . . . . . . . . . . Arm (including 34, 40, 41, 44 - 48). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044495-001 . . . . . . . Steer wheels (including 29 and 30). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045808 . . . . . . . . . . . Lift frame (including 35, 37 - 39). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

044511-101. . . . . . . . Load wheel (including 47 and 48). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

045852 . . . . . . . . . . . Steer wheels (including 27, 29 and 32). . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 1 1 1 1 1 1 1

Always specify the model and serial numbers.

PTH 50 Series

171

Notes:

172

MISCELLANEOUS

173

MISCELLANEOUS Decals and Labels PTH50 Decals and Labels PTH50

Fig. 81 PTH 50 Series

174

MISCELLANEOUS Decals and Labels PTH50 ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 069469 . . . . . . . . . . . Crown decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 069467 . . . . . . . . . . . Decal, Momentum PTH .........................................

3 . . . . . . . 869105-xxx . . . . . . . . Decal, Warning, keep hands clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . . . . . . . . . . . . . . . . . . Capacity plate (contact factory) ...................................

5 . . . . . . . 069106-xxx . . . . . . . . Decal, Warning, work operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

869290 . . . . . . . . . . . Decal (PTH50 GLV / with parking brake). . . . . . . . . . . . . . . . . . . . . . . . . . .

3 2 2 1 1 1

xxxxx-001 . . . . . . . . . German xxxxx-002 . . . . . . . . . French xxxxx-003 . . . . . . . . . Spanish xxxxx-004 . . . . . . . . . Dutch xxxxx-005 . . . . . . . . . Italian xxxxx-006 . . . . . . . . . English xxxxx-007 . . . . . . . . . Polish xxxxx-008 . . . . . . . . . Czech xxxxx-009 . . . . . . . . . Danish xxxxx-010 . . . . . . . . . Portuguese xxxxx-017 . . . . . . . . . Hungarian xxxxx-018 . . . . . . . . . Finnish xxxxx-019 . . . . . . . . . Norwegian xxxxx-020 . . . . . . . . . Swedish xxxxx-021 . . . . . . . . . Russian xxxxx-022 . . . . . . . . . Turkish xxxxx-023 . . . . . . . . . Slovakian xxxxx-024 . . . . . . . . . Greek

Always specify the model and serial numbers.

PTH 50 Series

175

MISCELLANEOUS Decals and Labels PTH50 PS Decals and Labels PTH50 PS

Fig. 82 PTH 50 Series

176

MISCELLANEOUS Decals and Labels PTH50 PS ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 869105-xxx . . . . . . . . Decal, Warning, keep hands clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 069467 . . . . . . . . . . . Decal, Momentum PTH .........................................

3 . . . . . . . 869289 . . . . . . . . . . . Decal, Warning, work operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . . . . . . . . . . . . . . . . . . Capacity plate (contact factory) ...................................

5 . . . . . . . 869290 . . . . . . . . . . . Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 069469 . . . . . . . . . . . Crown decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 2 2 1 1 2

xxxxx-001 . . . . . . . . . German xxxxx-002 . . . . . . . . . French xxxxx-003 . . . . . . . . . Spanish xxxxx-004 . . . . . . . . . Dutch xxxxx-005 . . . . . . . . . Italian xxxxx-006 . . . . . . . . . English xxxxx-007 . . . . . . . . . Polish xxxxx-008 . . . . . . . . . Czech xxxxx-009 . . . . . . . . . Danish xxxxx-010 . . . . . . . . . Portuguese xxxxx-017 . . . . . . . . . Hungarian xxxxx-018 . . . . . . . . . Finnish xxxxx-019 . . . . . . . . . Norwegian xxxxx-020 . . . . . . . . . Swedish xxxxx-021 . . . . . . . . . Russian xxxxx-022 . . . . . . . . . Turkish xxxxx-023 . . . . . . . . . Slovakian xxxxx-024 . . . . . . . . . Greek

Always specify the model and serial numbers.

PTH 50 Series

177

MISCELLANEOUS Decals and Labels PTH50 S Decals and Labels PTH50 S

Fig. 83 PTH 50 Series

178

MISCELLANEOUS Decals and Labels PTH50 S ITEM

PART NUMBER

NAME

QUANTITY

1 . . . . . . . 869105-xxx . . . . . . . . Decal, Warning, keep hands clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 . . . . . . . 069467 . . . . . . . . . . . Decal, Momentum PTH .........................................

3 . . . . . . . 869289 . . . . . . . . . . . Decal, Warning, work operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 . . . . . . . . . . . . . . . . . . . . . . . . Capacity plate (contact factory) ...................................

5 . . . . . . . 869290 . . . . . . . . . . . Decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 . . . . . . . 069469 . . . . . . . . . . . Crown decal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 2 2 1 1 2

xxxxx-001 . . . . . . . . . German xxxxx-002 . . . . . . . . . French xxxxx-003 . . . . . . . . . Spanish xxxxx-004 . . . . . . . . . Dutch xxxxx-005 . . . . . . . . . Italian xxxxx-006 . . . . . . . . . English xxxxx-007 . . . . . . . . . Polish xxxxx-008 . . . . . . . . . Czech xxxxx-009 . . . . . . . . . Danish xxxxx-010 . . . . . . . . . Portuguese xxxxx-017 . . . . . . . . . Hungarian xxxxx-018 . . . . . . . . . Finnish xxxxx-019 . . . . . . . . . Norwegian xxxxx-020 . . . . . . . . . Swedish xxxxx-021 . . . . . . . . . Russian xxxxx-022 . . . . . . . . . Turkish xxxxx-023 . . . . . . . . . Slovakian xxxxx-024 . . . . . . . . . Greek

Always specify the model and serial numbers.

PTH 50 Series

179

Notes:

180