Crown Forklift RT3010 Series Parts Manual 812698-006

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