Parts Manual
RT3010 Series U1-Parts.p65
1
02.05.02, 11:32
TABLE OF CONTENT
Printed in Germany
1
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Printed in Germany
M1.0-0000-0002 M1.0-0000-0002 2
TABLE OF CONTENT Table of Content MA – SAFETY
PAGE
SERIAL NR. CUT
REV.
Safety Symbols used in the Manual ....................................... 7 ................................................................ Rev.1 01/01
ITD – INTRODUCTION
PAGE
SERIAL NR. CUT
REV.
SERIAL NR. CUT
REV.
SERIAL NR. CUT
REV.
SERIAL NR. CUT
REV.
SERIAL NR. CUT
REV.
SERIAL NR. CUT
REV.
SERIAL NR. CUT
REV.
General .................................................................................. 11 Model-Number ........................................................................ 12
P-1.1 – LUBRICATION
PAGE
Lubrication Type ..................................................................... 15 Grease Intervals .................................................................... 16
DIA – ELECTRICAL DIAGRAMS
PAGE
Diagrams/Control Circuit ........................................................ 19 Diagrams/Control Circuit-Steering Motor ................................ 20
M/P – HYDRAULIC
PAGE
Hydraulic Schematic .............................................................. 23
SECTION 1 – COVERS
PAGE
Covers ................................................................................... 28 Caster Wheel ......................................................................... 30
SECTION 2 – HYDRAULIC PARTS
PAGE
Tube/Hose Layout .................................................................. 34 Pumpen Motor and Pump ...................................................... 36
SECTION 3 – DRIVE UNIT
PAGE
Gearbox ................................................................................. 40 Drive Motor ............................................................................ 42 .............................................................. Rev.1 04/02
SECTION 4 – ELEKTICAL
PAGE
SERIAL NR. CUT
REV.
SERIAL NR. CUT
REV.
SERIAL NR. CUT
REV.
Elektrical Parts ...................................................................... 46,48,50 Directional Switch .................................................................. 52 Wiring Harness ....................................................................... 54,56
SECTION 6 – STEERING
PAGE
Steering ................................................................................. 60,62
SECTION 7 – MAST/LIFT STRUCTURE
PAGE
Lift Structure .......................................................................... 66 .............................................................. Rev.1 04/02
SECTION 8 – CYLINDER
PAGE
SERIAL NR. CUT
REV.
Lift Cylinder ............................................................................ 70 .............................................................. Rev.1 04/02
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
M/P-IDX-2810 REV. 2 04/02 M1.0-0000-0003 33
TABLE OF CONTENT SECTION 10 – MISCELLANEOUS SERVICE INF.
PAGE
SERIAL NR. CUT
REV.
Battery Trolley ........................................................................ 74 This Manual contains 76 Pages
M/P-IDX-2810
4 4M1.0-0000-0004
MP-RT3010_Rev.2-GB 04/02 • Printed in Germany
SAFETY
Printed in Germany
5
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Printed in Germany
6 M1.0-0000-0006
SAFETY Safety Symbols used in the Manual
General Maintenance and Repair Safety Notes
To help guide you through the manual and to highlight particular danger areas, we have used graphic illustrations:
DANGER Read the safety notices in the truck Maintenance and Operator's Manuals.
DANGER
● Failure to do so could result in severe or fatal injuries to maintenance personnel and/ or other persons.
This symbol indicates life-threatening risks ● Failure to comply with this notice may result in severe or fatal injuries to yourself or other people.
WARNING This symbol indicates the risk of serious injury and/or serious material damage.
Motorised vehicles can be dangerous if maintenance and service are neglected. For this reason maintenance and inspections must be carried out at regular short intervals by trained personnel working to approved company guidelines.
DANGER Follow all national/local safety regulations applicable for maintenance work, e.g. for work on higher levels.
● Failure to comply with this notice may result in severe injuries to yourself or other people and/or serious material damage.
● Failure to do so could result in severe or fatal injuries to maintenance personnel and/ or other persons.
CAUTION This symbol indicates the risk of minor injury and/or minor material damage.
Maintenance and Repair 1.
Maintenance work must only be carried out in accordance with the test and maintenance program contained in the present Maintenance Manual and any applicable service notices.
2.
Only qualified and authorised personnel may carry out work on the truck.
3.
Always keep fire extinguishers in good working condition. Do not approach fluid levels or leaks with a naked flame.
4.
To clean, use a non flammable, non combustible cleaning solution which is groundwater-neutral. Only carry out cleaning with an oil separator. Protect the electrical system from dampness.
5.
Keep the service area clean, dry and well-ventilated.
6.
Do not allow oil to penetrate the ground or enter the draining system. Used oil must be recycled. Oil filters and desiccants must be treated as special waste products. Relevant applicable regulations must be followed.
7.
Neutralise and thoroughly rinse any spilled battery fluid immediately.
● Failure to comply with this notice may result in minor injuries to yourself or other people and/or minor material damage.
INFORMATION Contains additional information with supplementary notes and hints.
OPTION OPTION
These items relate to optional features not supplied with the standard version.
Printed in Germany
M/P-MA-0000
REV. 1 4/00 M1.0-0000-0007 77
SAFETY 8.
Keep the truck clean. This will facilitate the location of loose or faulty components.
9.
Make sure that capacity and data plates, warnings and labels are legible at all times.
10. Alterations or modifications by the owner or operator are not permitted without the express written authorisation from Crown. 11. Only use original Crown spare parts to ensure the reliability, safety and suitability of the Crown truck.
Before Operating the Truck ●
Check the safety devices.
●
Get into the driver's seat.
●
Check the operation of the lifting device, travel direction switch, speed control, steering, warning devices and brakes.
Warnings and Labels on the Truck During regular maintenance check that the warnings and labels on the truck are complete and legible.
Before Leaving the Truck ●
Stop the truck.
●
Clean any illegible labels.
●
Lower the fork carriage fully.
●
Replace any faulty or missing labels.
●
Apply the parking brake.
●
Turn off the travel switch and remove the key.
The order and meaning of the warnings and labels on the truck are described in section 10.9 of the parts manual.
●
Block all wheels when parking on an uneven surface.
Before Carrying out Work on the Truck ●
Raise the truck to free the drive wheel. Press the emergency Stop button and disconnect the battery.
●
Prevent the truck from rolling away.
●
Before carrying out work on the hoist frame, the lift mast or on the fork carriage: Block these parts according to maintenance instructions in order to prevent them from dropping.
●
Only carry out operational testing when there is sufficient room to manoeuvre, to avoid the risk of injury to yourself and others.
M/P-MA-0000
Printed in Germany
REV. 1 4/00
8 8M1.0-0000-0008
INTRODUCTION
Printed in Germany
9
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Printed in Germany
M1.0-0000-00010 M1.0-0000-00010 10
INTRODUCTION General The present manual is designed for Customer Service engineers who wish to familiarise themselves with the maintenance work required for the various truck components. It also contains troubleshooting sections which can be used to identify and remedy truck faults.
INFORMATION This book is not an operating manual. It is designed solely for specialist personnel who have been trained and authorised to carry out the work described in the manual.
Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this series. Brochures can be obtained from your CROWN dealer or from the following address:
CROWN Gabelstapler GmbH Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133
This manual therefore contains fewer and less detailed warnings than the Operator's Manual, as the latter is aimed at persons who have very little or no prior experience at all.
Operating Instructions This manual contains no operating instructions. An operating instructions manual is supplied with the vehicle. Additional copies can be ordered as required. With the help of this manual you and your personnel will be able to ensure the long service life, operational safety and error free functioning of your CROWN vehicle.
Service Training CROWN offers the appropriate vehicle related training for service personnel. Details on this training can be obtained from CROWN on request.
Ordering Spare Parts Spare parts can be ordered by quoting: ●
The truck specification number
●
The truck model number
●
The truck serial number
This information can be found on the truck's data plate. Only if this information is provided can the order be processed quickly, correctly and reliably.
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
M/P-ITD-2810
M1.0-0000-00011 11 11
INTRODUCTION Model-Number
RT3010 Modeldescription Low Level Order Picker, 2.000 kg capacity
M/P-ITD-2810
M1.0-0000-00012 1212
MP-RT3010_Rev.2-GB 04/02 • Printed in Germany
LUBRICATION AND ADJUSTMENT
Printed in Germany
13
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Printed in Germany
14M1.0-0000-00014
LUBRICATION Lubricant Type
Product Description
Manufacturer CROWN-Part-No.
Type
Grease (multi purpose)
Aralube HLP-2 LM-Grease Regulus A2 Beacon EP2 EP2 Mobiluxe E2 Retinax LX
Aral Castrol Century Esso Maxol Mobil Shell
053002-001
B
Low temperature grease
Aralube SKL2 Unirex Lotemp EP
Aral Mobil
053002-005
BB
Lubrication oil (chain)
Kowal 40 Essolube HDX Plus + 40 Delvac 1240
Aral Esso Mobil
053002-007
G
Low temperature lubrication oil
SHC 626
Mobil
053002-008
GG
Hydraulic oil
Vitam GF 32 Hyspin AWS-32 Nuto H32 DTE 24 Tellus 32
Aral Castrol Esso Mobil Shell
053001-003
D
Low temperature hydraulic oil
Univis J 13 Aero HFA
Aral Mobil
053001-008
DD
Transmission oil
Hyp 85W90 GX - D 85W90 Mobilube HD85/90 Spirax MB 90
Aral Esso Mobil Shell
053002-004
A
Low temperature transmission oil
Mobilube SHC
Mobil
053002-006
AA
Rubber and vinyl dressing
H
Special grease
MOS2 Lithium
Universal lubrication oil
SAE 40
Dow Corning
063002-022
M
C L01-gb
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
P-1.1-2810
M1.0-0000-00015 15 15
LUBRICATION Grease Points / Intervals Type
Vol.
100 hours
D
A/R
X
L-2 Replace hydraulic oil and filter
D
A/R
Initially after 500 service hours
L-3 All hinges
C
A/R
X
L-4 Grease steering linkage
B
A/R
X
L-5 Grease steering chain
G
A/R
X
L-6 Drive unit live ring bearing
B
A/R
X
L-7 Grease lifting mechanism
B
A/R
X
L-8 Lift cylinder attachment
B
A/R
X
L-9 Piston rod attachment
B
A/R
X
L-10 Change gear oil
A
A/R
Item Component L-1
Check hydraulic oil level, replenish if necessary
250 hours
500 hours
1000 hours
Initially after 250 service hours
2000 hours
X
X L08-GB
P-1.2-2810
M1.0-0000-00016 1616
MP-RT3010_Rev.2-GB 04/02 • Printed in Germany
ELECTRICAL DIAGRAMS
Printed in Germany
17
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Printed in Germany
M1.0-0000-00018 M1.0-0000-00018 18
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
BROWN BLACK BROWN/BLACK
WHITE VIOLET GREEN YELLOW BLACK RED
BLACK BROWN
RED/WHITE
BLUE RED
BLUE/BLACK BLUE/WHITE BLUE WHITE RED/WHITE VIOLET
RED
BLUE YELLOW/RED BLACK RED/WHITE
RED/GREEN BLAKE
RED/GREEN
YELLOW/RED
BROWN/YELLOW
YELLOW/RED
BROWN/YELLOW
GREY
GREY/BLACK
BROWN/YELLOW
VIOLET WHITE BLUE/WHITE YELLOW/BLACK
YELLOW/RED RED/GREEN
BLUE
BLUE
BROWN
BLACK GREY
BLACK BROWN BROWN
GREY/BLACK GREY/BLACK
YELLOW/RED
PINK
BLUE BLUE/BLACK YELLOW/RED
DIAGRAMS Control Circuit
M1797_gb
M/P-DIA-2810
M1.0-0000-00019 19 19
M1.0-0000-00020 2020
YELLOW
BROWN BLACK BROWN/BLACK
WHITE VIOLET GREEN YELLOW BLACK RED
BLACK BROWN
RED/WHITE
BLUE RED
BLUE/BLACK BLUE/WHITE BLUE WHITE RED/WHITE VIOLET
RED
BLUE YELLOW/RED BLACK RED/WHITE
RED/GREEN BLACK
RED/GREEN
YELLOW/RED
BROWN/YELLOW
GREY/BLACK WHITE/BLACK WHITE/GREEN
GREY YELLOW/BLACK YELLOW/RED
YELLOW/RED
BROWN/YELLOW
PINK
M/P-DIA-2810 PINK/BLACK
GREY/BLACK
BROWN/YELLOW
VIOLET WHITE BLUE/WHITE YELLOW/RED RED/GREEN
BLUE
BLUE
BROWN
BLACK GREY
BROWN BROWN
BLACK
YELLOW/BLACK
GREY/BLACK GREY/BLACK
YELLOW/RED
PINK
BLUE BLUE/BLACK YELLOW
DIAGRAMS
Control Circuit/Steering Motor
M1810_gb
MP-RT3010_Rev.2-GB 04/02 • Printed in Germany
RED/BLACK
HYDRAULIC SCHEMATIC
Printed in Germany
21
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Printed in Germany
M1.0-0000-00022 M1.0-0000-00022 22
HYDRAULIC SCHEMATIC
M1781 MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
M/P-HYD-2810
M1.0-0000-00023 23 23
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Printed in Germany
24
PARTS
Printed in Germany
25
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Printed in Germany
26M1.0-0000-00026
SECTION 1
Printed in Germany
27
COVERS
M1764 MP-1.0-2810
28M1.0-0000-00028
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
COVERS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809276-001 ............................ Screw ...................................................................................................... 8 2 ..................... 809210-004 ............................ Washer ................................................................................................... 8 3 ..................... 809277 .................................... Instrument Panel .................................................................................... 1 4 ..................... 809008-002 ............................ Handle .................................................................................................... 1 5 ..................... 809278-001 ............................ Support ................................................................................................... 1 6 ..................... 809279 .................................... Pad ......................................................................................................... 1 7 ..................... 809280-001 ............................ Nut .......................................................................................................... 1 8 ..................... 809278-002 ............................ Support ................................................................................................... 1 9 ..................... 809281 .................................... Cover ...................................................................................................... 1 10 ................... 809282-001 ............................ Fastener ................................................................................................. 2 11 ................... 809283 .................................... Hinge ...................................................................................................... 2 12 ................... 809232-004 ............................ Washer ................................................................................................... 4 13 ................... 809211-007 ............................ Screw ...................................................................................................... 4 14 ................... 809278-003 ............................ Support ................................................................................................... 1 15 ................... 809005-001 ............................ Washer ................................................................................................... 4 16 ................... 809006-002 ............................ Screw ...................................................................................................... 3 17 ................... 809284-001 ............................ Plug ........................................................................................................ 2 18 ................... 809285 .................................... Chassis .................................................................................................. 1 19 ................... 809276-002 ............................ Screw ...................................................................................................... 2 20 ................... 809006-008 ............................ Screw ...................................................................................................... 2 21 ................... 809004-002 ............................ Nut .......................................................................................................... 2 22 ................... 809286-001 ............................ Hose Clamp ........................................................................................... 1 23 ................... 809004-001 ............................ Nut .......................................................................................................... 1 24 ................... 809278-004 ............................ Support ................................................................................................... 1 25 ................... 809287 .................................... Fan .......................................................................................................... 2 26 ................... 809004-009 ............................ Nut .......................................................................................................... 8 27 ................... 809005-016 ............................ Washer ................................................................................................... 8 28 ................... 809142-003 ............................ Washer ................................................................................................... 8 29 ................... 809276-003 ............................ Screw ...................................................................................................... 8 30 ................... 809288 .................................... Finger Guard .......................................................................................... 2 31 ................... 809286-002 ............................ Hose Clamp ........................................................................................... 1 32 ................... 809006-012 ............................ Screw ...................................................................................................... 1 33 ................... 809278-005 ............................ Support ................................................................................................... 1 34 ................... 809005-007 ............................ Washer ................................................................................................... 1 35 ................... 809005-002 ............................ Washer ................................................................................................... 1 36 ................... 809276-004 ............................ Screw ...................................................................................................... 1 37 ................... 809296-002 ............................ Pin .......................................................................................................... 1 38 ................... 809276-005 ............................ Screw ...................................................................................................... 4 39 ................... 809289 .................................... Cover ...................................................................................................... 1 40 ................... 809290 .................................... Cover ...................................................................................................... 1 41 ................... 809006-005 ............................ Screw ...................................................................................................... 4 42 ................... 809291-001 ............................ Buffer ...................................................................................................... 2 43 ................... 809282-002 ............................ Fastener ................................................................................................. 2 44 ................... 809292 .................................... Lid ........................................................................................................... 1 45 ................... 809276-006 ............................ Screw ...................................................................................................... 3 46 ................... 809293 .................................... Floor Plate .............................................................................................. 1 47 ................... 809294 .................................... Floor Mat ................................................................................................ 1 48 ................... 809004-005 ............................ Nut .......................................................................................................... 1 49 ................... 809291-002 ............................ Buffer ...................................................................................................... 2 50 ................... 809295 .................................... Pedal ...................................................................................................... 1 51 ................... 809213-002 ............................ Spring ..................................................................................................... 1 52 ................... 809005-004 ............................ Washer ................................................................................................... 1 53 ................... 809276-007 ............................ Screw ...................................................................................................... 1 OPTIONAL 54 ................... 809278-006 ............................ Support ................................................................................................... 1 55 ................... 809006-004 ............................ Screw ...................................................................................................... 2 56 ................... 809280-002 ............................ Nut .......................................................................................................... 14 57 ................... 809005-017 ............................ Washer ................................................................................................... 14 58 ................... 809276-008 ............................ Screw ...................................................................................................... 14 59 ................... 809296-001 ............................ Pin .......................................................................................................... 7 60 ................... 809010-001 ............................ Roller ...................................................................................................... 7 Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-1.0-2810
29
CASTER WHEEL
M1766 MP-1.5-2810
30M1.0-0000-00030
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
CASTER WHEEL INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809006-004 ............................ Screw ...................................................................................................... 2 2 ..................... 809301 .................................... Cover ...................................................................................................... 1 3 ..................... 809276-011 ............................ Screw ...................................................................................................... 6 4 ..................... 809005-018 ............................ Washer ................................................................................................... 6 5 ..................... 809302 .................................... Flange .................................................................................................... 1 6 ..................... 809177-002 ............................ Bearing Ball ........................................................................................... 1 7 ..................... 809303 .................................... Hub ......................................................................................................... 1 8 ..................... 809304 .................................... Grease Nipple ........................................................................................ 1 9 ..................... 809305-001 ............................ Bushing .................................................................................................. 2 10 ................... 809280-003 ............................ Nut .......................................................................................................... 1 11 ................... 809005-019 ............................ Washer ................................................................................................... 1 12 ................... 809296-004 ............................ Pin .......................................................................................................... 1 13 ................... 809013-008 ............................ Spacer .................................................................................................... 2 14 ................... 809004-010 ............................ Nut .......................................................................................................... 2 15 ................... 809013-009 ............................ Spacer .................................................................................................... 2 16 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 4 17 ................... 809013-010 ............................ Spacer .................................................................................................... 2 18 ................... 809306 .................................... Wheel ..................................................................................................... 2 19 ................... 809307 .................................... Axle ......................................................................................................... 1 20 ................... 809296-005 ............................ Pin .......................................................................................................... 1 21 ................... 809308 .................................... Caster Wheel Assy ................................................................................ 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-1.5-2810
31
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Printed in Germany
32M1.0-0000-00032
SECTION 2
Printed in Germany
33
TUBE/HOSE LAYOUT
M1770 MP-2.1-2810
34M1.0-0000-00034
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
TUBE/HOSE LAYOUT INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809335-001 ............................ Connector .............................................................................................. 2 2 ..................... 809087 .................................... Hose ....................................................................................................... 1 3 ..................... 809335-002 ............................ Connector .............................................................................................. 1 4 ..................... 809336-001 ............................ Hose ....................................................................................................... 1 5 ..................... 809497 .................................... Nut .......................................................................................................... 2 6 ..................... 809337 .................................... Solenoid ................................................................................................. 2 7 ..................... 809335-003 ............................ Connector .............................................................................................. 2 8 ..................... 809498-001 ............................ Lower Valve ............................................................................................ 1 9 ..................... 809499 .................................... Valve Block ............................................................................................. 1 10 ................... 809341 .................................... Flow Compensating Valve ..................................................................... 1 11 ................... 809498-002 ............................ Lift Valve ................................................................................................. 1 12 ................... 809501 .................................... Nut .......................................................................................................... 1 13 ................... 809502 .................................... Solenoid Valve ....................................................................................... 1 14 ................... 809276-018 ............................ Screw ...................................................................................................... 2 15 ................... 809029-004 ............................ Gasket .................................................................................................... 7 16 ................... 809211-009 ............................ Screw ...................................................................................................... 3 17 ................... 809336-002 ............................ Hose ....................................................................................................... 1 18 ................... 809108 .................................... Manometer Connector ........................................................................... 1 19 ................... 809343 .................................... Manifold Block ....................................................................................... 1 20 ................... 809005-001 ............................ Washer ................................................................................................... 2 21 ................... 809005-006 ............................ Washer ................................................................................................... 2 22 ................... 809006-019 ............................ Screw ...................................................................................................... 2 23 ................... 809344 .................................... Pressure Switch ..................................................................................... 1 24 ................... 809345 .................................... Tank ........................................................................................................ 1 25 ................... 809346 .................................... Rubber Plate .......................................................................................... 1 26 ................... 809347 .................................... Plug ........................................................................................................ 1 27 ................... 809348 .................................... Oil Filter .................................................................................................. 1 28 ................... 809335-004 ............................ Connector .............................................................................................. 1 29 ................... 809349-001 ............................ O-Ring .................................................................................................... 1 30 ................... 809350-001 ............................ Pipe ........................................................................................................ 1 31 ................... 809350-002 ............................ Pipe ........................................................................................................ 1 32 ................... 809351 .................................... Non Return Valve ................................................................................... 1 33 ................... 809352 .................................... Pressure Valve ....................................................................................... 1 34 ................... 809353 .................................... Pump Support ........................................................................................ 1 35 ................... 809349-002 ............................ O-Ring .................................................................................................... 2 36 ................... 809276-021 ............................ Screw ...................................................................................................... 4 37 ................... 809435 .................................... Support ................................................................................................... 1 38 ................... 809005-003 ............................ Washer ................................................................................................... 4 39 ................... 809276-019 ............................ Screw ...................................................................................................... 4 40 ................... 809354 .................................... Link ......................................................................................................... 2 41 ................... 809005-022 ............................ Washer ................................................................................................... 2 42 ................... 809280-011 ............................ Nut .......................................................................................................... 2 43 ................... 809355 .................................... Hydraulic Unit ........................................................................................ 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-2.1-2810
35
PUMP MOTOR AND PUMP
M1771 MP-2.13-2810
36M1.0-0000-00036
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
PUMP MOTOR AND PUMP INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809356 .................................... Cover ...................................................................................................... 1 2 ..................... 809357-001 ............................ Circlip ..................................................................................................... 1 3 ..................... 809358-001 ............................ Spacer .................................................................................................... 1 4 ..................... 809359 .................................... Shield ..................................................................................................... 1 5 ..................... 809360 .................................... End Cover .............................................................................................. 1 6 ..................... 809361 .................................... Insulator ................................................................................................. 1 7 ..................... 809060-005 ............................ Spring ..................................................................................................... 4 8 ..................... 809362 .................................... Brush Kit ................................................................................................. 1 9 ..................... 809014-007 ............................ Bearing Ball ........................................................................................... 1 10 ................... 809357-002 ............................ Circlip ..................................................................................................... 1 11 ................... 809363 .................................... Armature ................................................................................................ 1 12 ................... 809358-002 ............................ Spacer .................................................................................................... 1 13 ................... 809014-008 ............................ Bearing Ball ........................................................................................... 1 14 ................... 809364 .................................... Motor Housing ....................................................................................... 1 15 ................... 809365 .................................... Drive End Plate ...................................................................................... 1 16 ................... 809367 .................................... Seal ........................................................................................................ 1 17 ................... 809358-003 ............................ Spacer .................................................................................................... 1 18 ................... 809026-008 ............................ O-Ring .................................................................................................... 1 19 ................... 809368 .................................... Tappet ..................................................................................................... 1 20 ................... 809369 .................................... Pump ...................................................................................................... 1 21 ................... 809005-024 ............................ Washer ................................................................................................... 2 22 ................... 809276-022 ............................ Screw ...................................................................................................... 2 23 ................... 809370 .................................... Pump Motor Assembly ........................................................................... 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-2.13-2810
37
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Printed in Germany
38M1.0-0000-00038
SECTION 3
Printed in Germany
39
GEAR BOX
M1774 MP-3.1-2810
40M1.0-0000-00040
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
GEAR BOX INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809211-010 ............................ Screw ...................................................................................................... 5 2 ..................... 809210-005 ............................ Washer ................................................................................................... 5 3 ..................... 809395 .................................... Rim ......................................................................................................... 1 4 ..................... 809396 .................................... Wheel (Vulkollan) ................................................................................. 1 809397 .................................... Wheel (Rubber) ..................................................................................... 1 5 ..................... 809398 .................................... Wheel Assembly (Vulkollan) ................................................................. 1 809399 .................................... Wheel Assembly (Rubber) .................................................................... 1 6 ..................... 809400-001 ............................ Seal ........................................................................................................ 1 7 ..................... 809069-007 ............................ Circlip ..................................................................................................... 1 8 ..................... 809175-004 ............................ Spacer .................................................................................................... 1 9 ..................... 809069-008 ............................ Circlip ..................................................................................................... 1 10 ................... 809014-009 ............................ Bearing Ball ........................................................................................... 2 11 ................... 809211-011 ............................ Screw ...................................................................................................... 1 12 ................... 809175-005 ............................ Spacer .................................................................................................... 4 13 ................... 809401-001 ............................ Gear ........................................................................................................ 1 14 ................... 809402 .................................... Housing .................................................................................................. 1 15 ................... 809400-002 ............................ Seal ........................................................................................................ 3 16 ................... 809403 .................................... Plug ........................................................................................................ 1 17 ................... 809005-005 ............................ Washer ................................................................................................... 3 18 ................... 809211-012 ............................ Screw ...................................................................................................... 3 19 ................... 809211-013 ............................ Screw ...................................................................................................... 9 20 ................... 809382 .................................... Washer ................................................................................................... 9 21 ................... 809211-015 ............................ Screw ...................................................................................................... 2 22 ................... 809349-003 ............................ O-Ring .................................................................................................... 1 23 ................... 809404 .................................... Grease Nipple ........................................................................................ 1 24 ................... 809405-001 ............................ Turntable ................................................................................................ 1 25 ................... 809211-014 ............................ Screw ...................................................................................................... 6 26 ................... 809405-002 ............................ Motor Flange .......................................................................................... 1 27 ................... 809401-002 ............................ Gear ........................................................................................................ 1 28 ................... 809349-004 ............................ O-Ring .................................................................................................... 1 29 ................... 809406 .................................... Gear ........................................................................................................ 1 30 ................... 809014-010 ............................ Bearing Ball ........................................................................................... 2 31 ................... 809176-006 ............................ Spacer .................................................................................................... 1 32 ................... 809401-003 ............................ Gear ........................................................................................................ 1 33 ................... 809280-005 ............................ Nut .......................................................................................................... 1 809407 .................................... Gear Box ................................................................................................ 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-3.1-2810
41
DRIVE MOTOR
M1775 MP-3.2-2810
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
REV.1 04/02
42M1.0-0000-00042
DRIVE MOTOR INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809408 .................................... Support ................................................................................................... 1 2 ..................... 809286-002 ............................ Hose Clamp ........................................................................................... 1 3 ..................... 809005-001 ............................ Washer ................................................................................................... 1 4 ..................... 809006-012 ............................ Screw ...................................................................................................... 1 5 ..................... 809190-001 ............................ Spring ..................................................................................................... 7 6 ..................... 809409 .................................... ElectroMagnet ........................................................................................ 1 7 ..................... 805033 .................................... Screw Kit ................................................................................................ 1 8 ..................... 807763-004 ............................ Rotor Friction .......................................................................................... 1 9 ..................... 809410 .................................... Magnetic (Brake) .................................................................................... 1 10 ................... 805030 .................................... Hub ......................................................................................................... 1 11 ................... 809411-001 ............................ Woodruff Key .......................................................................................... 1 12 ................... 809415 .................................... Spring & Brush Holder ........................................................................... AR 13 ................... 809412 .................................... Brush Kit ................................................................................................. 1 14 ................... 809400-003 ............................ Gasket .................................................................................................... 1 15 ................... 809413 .................................... Flange .................................................................................................... 1 16 ................... 809411-002 ............................ Woodruff Key .......................................................................................... 1 17 ................... 809231-002 ............................ Screw ...................................................................................................... 8 18 ................... 809414-001 ............................ Drive Motor ............................................................................................. 1 19 ................... 809604 .................................... Shield ..................................................................................................... 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-3.2-2810
REV.1 04/02
43
Page intentionally left blank
Printed in Germany
44M1.0-0000-00044
SECTION 4
Printed in Germany
45
ELECTRICAL PARTS
M1765 MP-4.0-2810
46M1.0-0000-00046
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
ELECTRICAL PARTS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809006-014 ............................ Screw ...................................................................................................... 4 2 ..................... 809297 .................................... Guide ...................................................................................................... 2 3 ..................... 809005-008 ............................ Washer ................................................................................................... 4 4 ..................... 809005-004 ............................ Washer ................................................................................................... 4 5 ..................... 809004-005 ............................ Nut .......................................................................................................... 4 6 ..................... 809298 .................................... Push ....................................................................................................... 1 7 ..................... 809278-007 ............................ Support ................................................................................................... 1 8 ..................... 809208-001 ............................ Nut .......................................................................................................... 4 9 ..................... 809210-001 ............................ Washer ................................................................................................... 8 10 ................... 809209 .................................... Switch ..................................................................................................... 2 11 ................... 809276-009 ............................ Screw ...................................................................................................... 4 12 ................... 809142-003 ............................ Washer ................................................................................................... 6 13 ................... 809005-016 ............................ Washer ................................................................................................... 6 14 ................... 809006-025 ............................ Screw ...................................................................................................... 2 15 ................... 809004-009 ............................ Nut .......................................................................................................... 4 16 ................... 809299 .................................... Circlip ..................................................................................................... 1 17 ................... 809296-003 ............................ Pin .......................................................................................................... 1 18 ................... 809276-010 ............................ Screw ...................................................................................................... 1 19 ................... 809065-005 ............................ Circlip ..................................................................................................... 1 20 ................... 809014-004 ............................ Bearing Ball ........................................................................................... 1 21 ................... 809003-007 ............................ Buffer ...................................................................................................... 4 22 ................... 809300 .................................... Support ................................................................................................... 1 23 ................... 809211-004 ............................ Screw ...................................................................................................... 3 24 ................... 809136 .................................... Motor ...................................................................................................... 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-4.0-2810
47
ELECTRICAL PARTS
M1777 MP-4.0-2810
48M1.0-0000-00048
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
ELECTRICAL PARTS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809436 .................................... Controller ............................................................................................... 1 2 ..................... 809231-002 ............................ Screw ...................................................................................................... 4 3 ..................... 809232-001 ............................ Washer ................................................................................................... 4 4 ..................... 809246 .................................... Support ................................................................................................... 1 5 ..................... 809243 .................................... Contactor ................................................................................................ 2 6 ..................... 809233-002 ............................ Nut .......................................................................................................... 4 7 ..................... 809172-001 ............................ Washer ................................................................................................... 4 8 ..................... 809231-003 ............................ Screw ...................................................................................................... 4 9 ..................... 809231-004 ............................ Screw ...................................................................................................... 2 10 ................... 809005-005 ............................ Washer ................................................................................................... 2 11 ................... 809004-005 ............................ Nut .......................................................................................................... 4 12 ................... 809005-002 ............................ Washer ................................................................................................... 4 13 ................... 809005-007 ............................ Washer ................................................................................................... 2 14 ................... 809416 .................................... Screw ...................................................................................................... 2 15 ................... 809417 .................................... Plate ....................................................................................................... 1 16 ................... 809418 .................................... Fuse ........................................................................................................ 2 17 ................... 809233-001 ............................ Nut .......................................................................................................... 7 18 ................... 809005-004 ............................ Washer ................................................................................................... 7 19 ................... 809232-003 ............................ Washer ................................................................................................... 6 20 ................... 809232-002 ............................ Washer ................................................................................................... 8 21 ................... 809241 .................................... Buffer ...................................................................................................... 4 22 ................... 809231-005 ............................ Screw ...................................................................................................... 1 23 ................... 809232-004 ............................ Washer ................................................................................................... 1 24 ................... 809275 .................................... Support ................................................................................................... 1 25 ................... 809419 .................................... Fuse ........................................................................................................ 1 26 ................... 809247 .................................... Fuse Holder ........................................................................................... 1 OPTIONAL 27 ................... 809249 .................................... Programmer ........................................................................................... 1 28 ................... 809250-001 ............................ Connector .............................................................................................. 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-4.0-2810
49
ELECTRICAL PARTS
M1778 MP-4.0-2810
50M1.0-0000-00050
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
ELECTRICAL PARTS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809420 .................................... Nut .......................................................................................................... 2 2 ..................... 809421 .................................... Handle .................................................................................................... 1 3 ..................... 809422-001 ............................ Power Cable .......................................................................................... 1 4 ..................... 809423 .................................... Battery Connector .................................................................................. 2 5 ..................... 809006-017 ............................ Screw ...................................................................................................... 4 6 ..................... 809005-001 ............................ Washer ................................................................................................... 4 7 ..................... 809422-002 ............................ Power Cable .......................................................................................... 1 8 ..................... 809424 .................................... Grommet ................................................................................................ 2 9 ..................... 809425 .................................... Support ................................................................................................... 1 10 ................... 809426 .................................... Holder ..................................................................................................... 1 11 ................... 809005-008 ............................ Washer ................................................................................................... 2 12 ................... 809005-004 ............................ Washer ................................................................................................... 2 13 ................... 809006-004 ............................ Screw ...................................................................................................... 2 14 ................... 809428-001 ............................ Battery 285 Ah ....................................................................................... 1 809428-002 ............................ Battery 315 Ah ....................................................................................... 1 15 ................... 809429 .................................... Battery Tray ............................................................................................. 1 16 ................... 809224-001 ............................ Push ....................................................................................................... 1 17 ................... 809225 .................................... Contact ................................................................................................... 1 18 ................... 809430 .................................... Discharge Meter .................................................................................... 1 19 ................... 809226 .................................... Keyswitch ............................................................................................... 1 20 ................... 809224-002 ............................ Push Button ............................................................................................ 3 21 ................... 809224-003 ............................ Push Button ............................................................................................ 1 22 ................... 809231-007 ............................ Screw ...................................................................................................... 6 23 ................... 809005-016 ............................ Washer ................................................................................................... 6 24 ................... 809142-003 ............................ Washer ................................................................................................... 6 25 ................... 809264 .................................... Switch ..................................................................................................... 2 26 ................... 809259 .................................... Horn ........................................................................................................ 1 27 ................... 809256 .................................... Switch ..................................................................................................... 1 28 ................... 809394 .................................... Support ................................................................................................... 1 29 ................... 809431 .................................... Hose clamp ............................................................................................ 1 30 ................... 809432 .................................... Support ................................................................................................... 1 31 ................... 809276-004 ............................ Screw ...................................................................................................... 2 OPTIONAL 32 ................... 809006-027 ............................ Screw ...................................................................................................... 4 33 ................... 809172-001 ............................ Washer ................................................................................................... 4 34 ................... 809232-004 ............................ Washer ................................................................................................... 6 35 ................... 809258 .................................... Power Control Unit (Steering) ............................................................... 1 36 ................... 809242-004 ............................ Fuse ........................................................................................................ 1 37 ................... 809242-005 ............................ Fuse ........................................................................................................ 1 38 ................... 809231-005 ............................ Screw ...................................................................................................... 2 39 ................... 809243 .................................... Contactor ................................................................................................ 1 40 ................... 809257-002 ............................ Buzzer .................................................................................................... 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-4.0-2810
51
DIRECTIONAL SWITCH
M1776 MP-4.6-2810
52M1.0-0000-00052
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
DIRECTIONAL SWITCH INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809203-001 ............................ Circlip ..................................................................................................... 1 2 ..................... 809204 .................................... Gear ........................................................................................................ 1 3 ..................... 809205 .................................... Cam ........................................................................................................ 1 4 ..................... 809206-001 ............................ Support ................................................................................................... 2 5 ..................... 809207 .................................... Potentiometer ......................................................................................... 1 6 ..................... 809208-001 ............................ Nut .......................................................................................................... 6 7 ..................... 809209 .................................... Switch ..................................................................................................... 2 8 ..................... 809210-001 ............................ Washer ................................................................................................... 4 9 ..................... 809211-001 ............................ Screw ...................................................................................................... 5 10 ................... 809211-002 ............................ Screw ...................................................................................................... 1 11 ................... 809212-001 ............................ Support ................................................................................................... 1 12 ................... 809213-001 ............................ Spring ..................................................................................................... 1 13 ................... 809214 .................................... Holder ..................................................................................................... 1 14 ................... 809210-002 ............................ Washer ................................................................................................... 1 15 ................... 809211-003 ............................ Screw ...................................................................................................... 1 16 ................... 809215-001 ............................ Shaft ....................................................................................................... 1 17 ................... 809216 .................................... Lever ...................................................................................................... 1 18 ................... 809211-004 ............................ Screw ...................................................................................................... 2 19 ................... 809203-002 ............................ Circlip ..................................................................................................... 2 20 ................... 809210-003 ............................ Washer ................................................................................................... 2 21 ................... 809217 .................................... Bushing .................................................................................................. 2 22 ................... 809142-003 ............................ Washer ................................................................................................... 1 23 ................... 809218 .................................... Pin .......................................................................................................... 1 24 ................... 809206-002 ............................ Support ................................................................................................... 1 25 ................... 809005-002 ............................ Washer ................................................................................................... 2 26 ................... 809006-015 ............................ Screw ...................................................................................................... 2 27 ................... 809219 .................................... Accelerator ............................................................................................. 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-4.6-2810
53
WIRING HARNESS
Instrument Board Armaturenbrett Tablleau de bord Accelerator Fahrgeber Accelerateur
M1779 MP-4.11-2810
54M1.0-0000-00054
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
WIRING HARNESS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 2 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 3 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 4 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 5 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 6 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 7 ..................... 809433-002 ............................ Cable ...................................................................................................... 1 8 ..................... 809433-002 ............................ Cable ...................................................................................................... 1 9 ..................... 809433-002 ............................ Cable ...................................................................................................... 1 10 ................... 809433-002 ............................ Cable ...................................................................................................... 1 11 ................... 809433-002 ............................ Cable ...................................................................................................... 1 12 ................... 809433-002 ............................ Cable ...................................................................................................... 1 13 ................... 809433-003 ............................ Cable ...................................................................................................... 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-4.11-2810
55
WIRING HARNESS
Instrument Board Armaturenbrett Tablleau de bord Accelerator Fahrgeber Accelerateur
M1780 MP-4.11-2810
56M1.0-0000-00056
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
WIRING HARNESS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 2 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 3 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 4 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 5 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 6 ..................... 809433-001 ............................ Cable ...................................................................................................... 1 7 ..................... 809433-002 ............................ Cable ...................................................................................................... 1 8 ..................... 809433-002 ............................ Cable ...................................................................................................... 1 9 ..................... 809433-002 ............................ Cable ...................................................................................................... 1 10 ................... 809433-002 ............................ Cable ...................................................................................................... 1 11 ................... 809433-002 ............................ Cable ...................................................................................................... 1 12 ................... 809433-002 ............................ Cable ...................................................................................................... 1 13 ................... 809433-004 ............................ Cable ...................................................................................................... 1 14 ................... 809433-004 ............................ Cable ...................................................................................................... 1 15 ................... 809433-004 ............................ Cable ...................................................................................................... 1 16 ................... 809433-004 ............................ Cable ...................................................................................................... 1 17 ................... 809433-004 ............................ Cable ...................................................................................................... 1 18 ................... 809433-005 ............................ Cable ...................................................................................................... 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-4.11-2810
57
Page intentionally left blank
Printed in Germany
58M1.0-0000-00058
SECTION 6
Printed in Germany
59
STEERING
M1772 MP-6.4-2810
60M1.0-0000-00060
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
STEERING INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809284-002 ............................ Plug ........................................................................................................ 1 2 ..................... 809371 .................................... Knob ....................................................................................................... 1 3 ..................... 809372 .................................... Steering Wheel ...................................................................................... 1 4 ..................... 809006-029 ............................ Screw ...................................................................................................... 1 5 ..................... 809005-005 ............................ Washer ................................................................................................... 1 6 ..................... 809005-009 ............................ Washer ................................................................................................... 1 7 ..................... 809371-001 ............................ Woodruff Key .......................................................................................... 1 8 ..................... 809374 .................................... Shaft ....................................................................................................... 1 9 ..................... 809373-002 ............................ Woodruff Key .......................................................................................... 1 10 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 4 11 ................... 809069-006 ............................ Circlip ..................................................................................................... 3 12 ................... 809376-001 ............................ Gear ........................................................................................................ 1 13 ................... 809377 .................................... Spacer .................................................................................................... 3 14 ................... 809069-001 ............................ Circlip ..................................................................................................... 2 15 ................... 809378 .................................... Chain ...................................................................................................... 1 16 ................... 809379-001 ............................ Link Extended ........................................................................................ 1 17 ................... 809376-002 ............................ Gear ........................................................................................................ 1 18 ................... 809305-007 ............................ Bushing .................................................................................................. 1 19 ................... 809296-015 ............................ Pin .......................................................................................................... 1 20 ................... 809376-003 ............................ Gear ........................................................................................................ 1 21 ................... 809380-001 ............................ Tappet ..................................................................................................... 1 22 ................... 809299 .................................... Circlip ..................................................................................................... 3 23 ................... 809381 .................................... Shaft ....................................................................................................... 1 24 ................... 809373-003 ............................ Woodruff Key .......................................................................................... 2 25 ................... 809014-008 ............................ Bearing Ball ........................................................................................... 2 26 ................... 809375-001 ............................ Circlip ..................................................................................................... 1 27 ................... 809276-011 ............................ Screw ...................................................................................................... 1 28 ................... 809004-002 ............................ Nut .......................................................................................................... 2 29 ................... 809278-009 ............................ Support ................................................................................................... 1 30 ................... 809382 .................................... Washer ................................................................................................... 3 31 ................... 809142-001 ............................ Washer ................................................................................................... 2 32 ................... 809276-019 ............................ Screw ...................................................................................................... 2 33 ................... 809269-016 ............................ Pin .......................................................................................................... 2 34 ................... 809383 .................................... Cardan shaft .......................................................................................... 1 35 ................... 809375-002 ............................ Circlip ..................................................................................................... 1 36 ................... 809005-008 ............................ Washer ................................................................................................... 4 37 ................... 809005-004 ............................ Washer ................................................................................................... 4 38 ................... 809006-007 ............................ Screw ...................................................................................................... 4 39 ................... 809278-010 ............................ Support ................................................................................................... 1 40 ................... 809384 .................................... Shaft ....................................................................................................... 1 41 ................... 809144 .................................... Link Extended ........................................................................................ 2 42 ................... 809379-002 ............................ Link Extended ........................................................................................ 1 43 ................... 809376-004 ............................ Gear ........................................................................................................ 1 44 ................... 809145 .................................... Chain ...................................................................................................... 1 45 ................... 809385 .................................... Chain Adjuster ....................................................................................... 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-6.4-2810
61
STEERING
M1773 MP-6.4-2810
62M1.0-0000-00062
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
STEERING INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809284-002 ............................ Plug ........................................................................................................ 1 2 ..................... 809371 .................................... Knob ....................................................................................................... 1 3 ..................... 809372 .................................... Steering Wheel ...................................................................................... 1 4 ..................... 809006-029 ............................ Screw ...................................................................................................... 3 5 ..................... 809005-005 ............................ Washer ................................................................................................... 3 6 ..................... 809005-009 ............................ Washer ................................................................................................... 1 7 ..................... 809371-001 ............................ Woodruff Key .......................................................................................... 1 8 ..................... 809386 .................................... Shaft ....................................................................................................... 1 9 ..................... 809006-026 ............................ Screw ...................................................................................................... 1 10 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 1 11 ................... 809305-008 ............................ Bushing .................................................................................................. 1 12 ................... 809276-024 ............................ Screw ...................................................................................................... 1 13 ................... 809014-014 ............................ Bearing Ball ........................................................................................... 1 14 ................... 809299 .................................... Circlip ..................................................................................................... 1 15 ................... 809142-003 ............................ Washer ................................................................................................... 14 16 ................... 809003-007 ............................ Buffer ...................................................................................................... 4 17 ................... 809005-016 ............................ Washer ................................................................................................... 13 18 ................... 809004-009 ............................ Nut .......................................................................................................... 4 19 ................... 809231-001 ............................ Screw ...................................................................................................... 3 20 ................... 809135-002 ............................ Flange .................................................................................................... 1 21 ................... 809136 .................................... Motor ...................................................................................................... 1 22 ................... 809005-025 ............................ Washer ................................................................................................... 2 23 ................... 809276-025 ............................ Screw ...................................................................................................... 2 24 ................... 809387 .................................... Shield ..................................................................................................... 1 25 ................... 809060-006 ............................ Spring ..................................................................................................... 2 26 ................... 809388 .................................... Brush Kit ................................................................................................. 1 27 ................... 809373-004 ............................ Woodruff Key .......................................................................................... 1 28 ................... 809389 .................................... Motor ...................................................................................................... 1 29 ................... 809390 .................................... Gear Box ................................................................................................ 1 30 ................... 809278-011 ............................ Support ................................................................................................... 1 31 ................... 809005-004 ............................ Washer ................................................................................................... 4 32 ................... 809006-014 ............................ Screw ...................................................................................................... 4 33 ................... 809142-001 ............................ Washer ................................................................................................... 2 34 ................... 809382 .................................... Washer ................................................................................................... 2 35 ................... 809276-019 ............................ Screw ...................................................................................................... 2 36 ................... 809391 .................................... Gear ........................................................................................................ 1 37 ................... 809005-026 ............................ Washer ................................................................................................... 1 38 ................... 809005-027 ............................ Washer ................................................................................................... 1 39 ................... 809005-002 ............................ Washer ................................................................................................... 1 40 ................... 809006-012 ............................ Screw ...................................................................................................... 1 41 ................... 809145 .................................... Chain ...................................................................................................... 1 42 ................... 809144 .................................... Link Extended ........................................................................................ 2 43 ................... 809385 .................................... Chain Adjuster ....................................................................................... 1 44 ................... 809231-007 ............................ Screw ...................................................................................................... 6 45 ................... 809264 .................................... Switch ..................................................................................................... 2 46 ................... 809392 .................................... Support ................................................................................................... 1 47 ................... 809006-027 ............................ Screw ...................................................................................................... 2 48 ................... 809172-001 ............................ Washer ................................................................................................... 2 49 ................... 809393-001 ............................ Cam ........................................................................................................ 1 50 ................... 809393-002 ............................ Cam ........................................................................................................ 1 51 ................... 809231-005 ............................ Screw ...................................................................................................... 4 52 ................... 809256 .................................... Switch ..................................................................................................... 1 53 ................... 809394 .................................... Support ................................................................................................... 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-6.4-2810
63
Page intentionally left blank
Printed in Germany
64M1.0-0000-00064
SECTION 7
Printed in Germany
65
LIFT STRUCTURE
M1769 MP-7.8-2810
66M1.0-0000-00066
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
LIFT STRUCTURE INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809276-014 ............................ Screw ...................................................................................................... 6 2 ..................... 809319 .................................... Cover ...................................................................................................... 1 3 ..................... 809006-033 ............................ Screw ...................................................................................................... 1 4 ..................... 809005-003 ............................ Washer ................................................................................................... 1 5 ..................... 809002-003 ............................ Gas Strut ................................................................................................ 1 6 ..................... 809434 .................................... Forks ....................................................................................................... 1 7 ..................... 809320 .................................... Cover ...................................................................................................... 1 8 ..................... 809276-015 ............................ Screw ...................................................................................................... 4 9 ..................... 809069-002 ............................ Circlip ..................................................................................................... 12 10 ................... 809296-008 ............................ Pin .......................................................................................................... 6 11 ................... 809321 .................................... Roller ...................................................................................................... 6 12 ................... 809069-006 ............................ Circlip ..................................................................................................... 6 13 ................... 809013-004 ............................ Spacer .................................................................................................... 4 14 ................... 809078 .................................... Guide ...................................................................................................... 4 15 ................... 809013-014 ............................ Spacer .................................................................................................... 8 16 ................... 809322 .................................... Lever ...................................................................................................... 4 17 ................... 809305-009 ............................ Bushing .................................................................................................. 6 18 ................... 809280-007 ............................ Nut .......................................................................................................... 2 19 ................... 809605 .................................... Washer ................................................................................................... 2 20 ................... 809305-002 ............................ Bushing .................................................................................................. 4 21 ................... 809323 .................................... Link (RH) ................................................................................................ 1 22 ................... 809323 .................................... Link (LH) ................................................................................................ 1 23 ................... 809305-008 ............................ Bushing .................................................................................................. 2 24 ................... 809296-009 ............................ Pin .......................................................................................................... 2 25 ................... 809324 .................................... Plate ....................................................................................................... 2 26 ................... 809006-015 ............................ Screw ...................................................................................................... 4 27 ................... 809276-013 ............................ Screw ...................................................................................................... 2 28 ................... 809004-002 ............................ Nut .......................................................................................................... 2 29 ................... 809269-017 ............................ Split pin .................................................................................................. 2 30 ................... 809269-018 ............................ Pin .......................................................................................................... 2 31 ................... 809325 .................................... Link ......................................................................................................... 1 32 ................... 809296-010 ............................ Pin .......................................................................................................... 2 33 ................... 809326 .................................... Link (RH) ................................................................................................ 1 34 ................... 809326 .................................... Link (LH) ................................................................................................ 1 35 ................... 809296-011 ............................ Pin .......................................................................................................... 2 36 ................... 809327 .................................... Plate ....................................................................................................... 2 37 ................... 809013-015 ............................ Spacer .................................................................................................... 4 38 ................... 809065-002 ............................ Ball joint ................................................................................................. 2 39 ................... 809280-008 ............................ Nut .......................................................................................................... 2 40 ................... 809328 .................................... Tension Bar ............................................................................................ 2 41 ................... 809054 .................................... Bushing .................................................................................................. 2 42 ................... 809305-004 ............................ Bushing .................................................................................................. 2 43 ................... 809296-012 ............................ Pin .......................................................................................................... 2 44 ................... 809296-013 ............................ Pin .......................................................................................................... 2 45 ................... 809304 .................................... Grease Nipple ........................................................................................ 2 46 ................... 809329 .................................... Riser ....................................................................................................... 2 47 ................... 809296-014 ............................ Pin .......................................................................................................... 2 48 ................... 809276-002 ............................ Screw ...................................................................................................... 2 49 ................... 809305-005 ............................ Bushing .................................................................................................. 4 50 ................... 809305-006 ............................ Bushing .................................................................................................. 4 51 ................... 809330 .................................... Plate Side ............................................................................................... 4 52 ................... 809276-016 ............................ Screw ...................................................................................................... 4 53 ................... 809276-017 ............................ Screw ...................................................................................................... 4 54 ................... 809331 .................................... Axle ......................................................................................................... 4 55 ................... 809332 .................................... Ring ........................................................................................................ 8 56 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 8 57 ................... 809333 .................................... Load Roller (Vulkollan) .......................................................................... 4 58 ................... 809334 .................................... Riser Assembly ...................................................................................... 2
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-7.8-2810
REV. 1 04/02
67
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Printed in Germany
68M1.0-0000-00068
SECTION 8
Printed in Germany
69
LIFT CYLINDER
M1768 MP-8.4-2810
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
REV.1 04/02
70M1.0-0000-00070
LIFT CYLINDER INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809314 .................................... Cylinder Tube ......................................................................................... 1 2 ..................... 809280-005 ............................ Nut .......................................................................................................... 1 3 ..................... 809315 .................................... Ring Retaining ....................................................................................... 1 4 ..................... 809028 .................................... Piston ...................................................................................................... 1 5 ..................... 809026-002 ............................ Ring ........................................................................................................ 1 6 ..................... 809029-001 ............................ Gasket .................................................................................................... 1 7 ..................... 809316 .................................... Piston Rod ............................................................................................. 1 8 ..................... 809026-001 ............................ O-Ring .................................................................................................... 1 9 ..................... 809317 .................................... Cylinder Nut ........................................................................................... 1 10 ................... 809024-001 ............................ Seal ........................................................................................................ 1 11 ................... 809023-001 ............................ Wiper ...................................................................................................... 1 12 ................... 809280-006 ............................ Nut .......................................................................................................... 1 13 ................... 809023-001 ............................ Rod End ................................................................................................. 1 14 ................... 809318 .................................... Cylinder Assembly ................................................................................. 1 (without 13) 809033-001 ............................ Seal Kit ................................................................................................... 1 (incl. 5,6,8,10,11)
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-8.4-2810
REV. 1 04/02
71
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Printed in Germany
72M1.0-0000-00072
SECTION 10
Printed in Germany
73
BATTERY TROLLEY
M1767 MP-10.0-2810
74M1.0-0000-00074
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
BATTERY TROLLEY INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 809309 .................................... Chassis .................................................................................................. 1 2 ..................... 809310 .................................... Wheel ..................................................................................................... 3 3 ..................... 809311 .................................... Tiller ........................................................................................................ 1 4 ..................... 809060-004 ............................ Spring ..................................................................................................... 1 5 ..................... 809296-006 ............................ Pin .......................................................................................................... 1 6 ..................... 809069-001 ............................ Circlip ..................................................................................................... 2 7 ..................... 809280-004 ............................ Nut .......................................................................................................... 1 8 ..................... 809013-011 ............................ Spacer .................................................................................................... 2 9 ..................... 809014-006 ............................ Bearing Ball ........................................................................................... 6 10 ................... 809312 .................................... Wheel ..................................................................................................... 3 11 ................... 809013-012 ............................ Spacer .................................................................................................... 1 12 ................... 809276-012 ............................ Screw ...................................................................................................... 1 13 ................... 809004-002 ............................ Nut .......................................................................................................... 4 14 ................... 809142-001 ............................ Washer ................................................................................................... 4 15 ................... 809278-008 ............................ Support ................................................................................................... 1 16 ................... 809276-013 ............................ Screw ...................................................................................................... 4 17 ................... 809013-013 ............................ Spacer .................................................................................................... 4 18 ................... 809296-007 ............................ Pin .......................................................................................................... 2 809313 .................................... Battery Trolley Assembly ........................................................................ 1
Always Specify Model & Serial Number MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
MP-10.0-2810
75
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Printed in Germany
76M1.0-0000-00076
CROWN Gabelstapler GmbH & Co. KG - European Headquarter Moosacher Str. 52 80809 Munich Germany Telephone +49 (0)89 93 00 2 - 0 Telefax +49 (0)89 93 00 2 -175 or -133
Printed in Germany • Revision Level C Order Number: 812698-006