Parts Manual
ST3000 Series Printed in Germany ● Revision Level A Order Number: 812708-006
This master manual is subject to continual updates. It is meant exclusively for businesses authorized by CROWN. It is not permitted to pass on the contents or copies thereof to third parties.
CROWN Gabelstapler GmbH & Co. KG - European Headquarter Moosacher Str. 52 80809 Munich Germany Phone +49 (0)89 93 00 2 - 0 Fax +49 (0)89 93 00 2 - 133
All rights reserved under international and Pan-American Copyright Agreement. Copyright 2002 CROWN Equipment Corporation
TABLE OF CONTENT
Printed in Germany
1
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Printed in Germany
M1.0-0000-0002 M1.0-0000-0002 2
TABLE OF CONTENT Table of Content ITD – INTRODUCTION
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General ................................................................................. 7
SECTION 1 – COVERS
PAGE
Covers................................................................................... 12 Outriggers ............................................................................. 14 Caster Wheel ........................................................................ 16
SECTION 2 – HYDRAULIC PART
PAGE
Tube-/Hose Layout ................................................................ 20 Hydraulic TT Mast ................................................................. 22
SECTION 3 – DRIVE UNIT
PAGE
Gearbox ................................................................................. 26 Drive Motor ........................................................................... 28 Knuckel ................................................................................. 30
SECTION 4 – ELECTRICAL
PAGE
Electrical Parts ..................................................................... 34, 36, 38 Contactor .............................................................................. 40 Control Handle ...................................................................... 42, 44 Charger ................................................................................. 46 Batteries ................................................................................ 48 Instrument ............................................................................. 50 Reverse Alarm ...................................................................... 52 Strobe Light ........................................................................... 54
SECTION5 – BRAKE SYSTEM
PAGE
Brake ..................................................................................... 58
SECTION 7 – MAST-/LIFT STRUCTURE
PAGE
TL Mast ................................................................................. 62 TL Mast - Chain .................................................................... 64 TT Mast ................................................................................. 66 TT Mast - Chain .................................................................... 68 Fork Carriage ........................................................................ 70 Mast Safty Screen ................................................................ 72 Forks ..................................................................................... 74 Load Backrest ....................................................................... 76 Yoke ...................................................................................... 80
SECTION 8 – CYLINDER
PAGE
Lift Cylinder ........................................................................... 82 Free Lift Cylinder ................................................................... 84
SECTION10 – MISCELLANEOUS SERVICE INF.
PAGE
Labels and Decals ................................................................. 88
MP-ST3000-GB 10/04 • Printed in Germany
MP-IDX-3130
M1.0-0000-0003 33
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Printed in Germany
4
INTRODUCTION
Printed in Germany
5
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Printed in Germany
M1.0-0000-0006 M1.0-0000-0006 6
INTRODUCTION Important customer information
Ordering Spare Parts
To ensure the safety of the truck, you, the customer, must only carry out maintenance and repairs as stipulated in the operator manual.
Spare parts can be ordered by quoting: ●
The truck specification number
Any additional work must be performed by Crown authorised service technicians. Authorised service technicians have the required expertise and up-to-date service information.
●
The truck model number
●
The truck serial number
If you wish to have your own technicians trained, please contact Crown for relevant training courses.
Subsequent Attachments and Modifications made to the Truck DANGER! Any proposed modification which would alter the original condition of the truck when delivered, must first be assessed and approved in writing by Crown Gabelstapler GmbH. ●
The net weight and position of attachments may considerably affect the capacity and other truck characteristics.
●
Changing the electrical system or adding electrically operated components may result in operating faults.
This information can be found on the truck's data plate. Only if this information is provided can the order be processed quickly, correctly and reliably. Please refer to the Technical Specifications Sheet for the utilisable loads, technical data and dimensions for this series. Brochures can be obtained from your CROWN dealer or from the following address:
CROWN Gabelstapler GmbH & CoKG Moosacher Str. 52 80809 Munich GERMANY Tel.: +49 (0)89 / 93 002 -0 Fax: +49 (0)89 / 93 002 -175 oder 133
Modifications which have not been assessed may result in fatal accidents!
MP-ST3000-GB 10/04 • Printed in Germany
M/P-ITD-3130
M1.0-0000-0007 77
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Printed in Germany
8
PARTS
Printed in Germany
9
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Printed in Germany
10M1.0-0000-00010
SECTION 1
Printed in Germany
11
COVERS
2 1 4
3
to Knuckle 12 11
6
A
26
23 7
9 10
25
8
21
5 22 24
18 20 16
14 13
19
A 15
17
MP-3130-101 MP-1.0-3130
12M1.0-0000-00012
MP-ST3000-GB 10/04 • Printed in Germany
COVERS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 813342 ..................................... Knuckle Cover ........................................................................................ 1 2 ..................... 050005-086 .............................. Screw ...................................................................................................... 2 3 ..................... 813275-002 .............................. Cover (without Charger) ......................................................................... 1 813496-002 .............................. Cover (with Charger & UK-Plug) ............................................................. 1 4 ..................... 050003-067 .............................. Screw ...................................................................................................... 5 5 ..................... 805825-001 .............................. Blind Rivet Nut ........................................................................................ 4 6 ..................... 813537-331 .............................. Cover (without Charger) ......................................................................... 1 813537-332 .............................. Cover (with Charger) .............................................................................. 1 813537-333 .............................. Cover (with Charger/UK-Plug) ................................................................ 1 7 ..................... 813152 ..................................... Cover ...................................................................................................... 1 8 ..................... 050077-013 .............................. Screw ...................................................................................................... 2 9 ..................... 109127-001 .............................. Clip Arrow Indicator (Green) ................................................................... 1 10 .................... 109127-003 .............................. Clip Arrow Indicator (Red) ...................................................................... 1 11 .................... 805818 ..................................... Spacer .................................................................................................... 6 12 .................... 803469-007 .............................. Screw ...................................................................................................... 6 13 .................... 050010-061 .............................. Washer ................................................................................................... 2 050009-057 .............................. Washer (0,5 mm) .................................................................................... AR 050009-058 .............................. Washer (1,0 mm) .................................................................................... AR 050009-059 .............................. Washer (2,0 mm) .................................................................................... AR 14 .................... 050008-057 .............................. Nut .......................................................................................................... 2 15 .................... 813261 ..................................... Threaded Boss ....................................................................................... 2 16 .................... 811617-001 .............................. Sidecover ................................................................................................ 1 17 .................... 811617-002 .............................. Sidecover ................................................................................................ 1 18 .................... 812933 ..................................... Wing Nut ................................................................................................. 2 19 .................... 811572 ..................................... Power Unit Frame ................................................................................... 1 20 .................... 812952 ..................................... Battery Cover Assembly (included 21 - 26) ............................................ 1 21 .......................... 812953 ..................................... Tray ................................................................................................... 1 055055-021 .............................. Sheating ............................................................................................ 3 22 .......................... 812956-001 .............................. Rubber End Cap ............................................................................... 1 23 .......................... 812956-002 .............................. Rubber End Cap ............................................................................... 1 24 .......................... 050067-012 .............................. Screw ................................................................................................ 8 053050-006 .............................. Screw Locking ................................................................................... AR 25 .......................... 804834-012 .............................. Cord .................................................................................................. 1 26 .......................... 813790 ..................................... Mat .................................................................................................... 1 053050-010 .............................. Adhesive ........................................................................................... AR
813522-101 Cover Assembly (without Charger/included 6, 7, 9 - 12) ........................................................ 1 813522-102 Cover Assembly (with Charger/included 6, 7, 9 - 12) ............................................................. 1 813522-103 Cover Assembly (with Charger/UK-Plug/included 6, 7, 9 - 12) .............................................. 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-1.0-3130
13
OUTRIGGERS
6
5 4 4 10 11
9 9
Torque Bolts 385 Nm
8 8
0
7
4
2
3 5 10 11 6
1
Power Unit see Section 01.0
9 9 8 7
8
3
MP-3130-103 MP-1.1-3130
14M1.0-0000-00014
MP-ST3000-GB 10/04 • Printed in Germany
OUTRIGGERS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 814370 ..................................... Outrigger (965 mm) ................................................................................. 1 814711 ..................................... Outrigger (864 mm) ................................................................................. 1 2 ..................... 814369 ..................................... Outrigger (965 mm) ................................................................................. 1 814712 ..................................... Outrigger (864 mm) ................................................................................. 1 3 ..................... 811422 ..................................... Clamp ...................................................................................................... 2 4 ..................... 050007-071 .............................. Screw ...................................................................................................... 4 5 ..................... 110454 ..................................... Axle ......................................................................................................... 2 6 ..................... 060009-083 .............................. Retaining Ring ........................................................................................ 2 7 ..................... 813081-100 .............................. Loadwheel ............................................................................................... 2 8 ..................... 055002-027 .............................. Bearing ................................................................................................... 2 9 ..................... 813081-200 .............................. String Guard ............................................................................................ 2 10 .................... 050006-052 .............................. Screw ...................................................................................................... 2 11 .................... 050008-030 .............................. Nut .......................................................................................................... 2
813081-001 .............................. Loadwheel Assembly (included 7 - 9) ..................................................... 2
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-1.1-3130
15
CASTER WHEEL
14 17 4 5
4 18 14
16 19
13
15
12 11 10
9
6
8
8
7 2 3 1 3
MP-3130-102 MP-1.5-3130
16M1.0-0000-00016
MP-ST3000-GB 10/04 • Printed in Germany
CASTER WHEEL INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ........................................................................ Caster Bracket ....................................................................................... 1 2 ..................... 805888-009 .............................. Axle ......................................................................................................... 1 3 ..................... 050000-047 .............................. Roll Pin ................................................................................................... 4 4 ..................... 055002-027 .............................. Bearing Ball ............................................................................................. 2 5 ..................... 813129 ..................................... Wheel ...................................................................................................... 1 6 ........................................................................ Caster Rig ............................................................................................... 1 7 ..................... 805888-008 .............................. Shaft ........................................................................................................ 1 8 ..................... 051058-013 .............................. Bearing Ball ............................................................................................. 2 9 ..................... 805888-002 .............................. Spring ..................................................................................................... 2 10 .................... 805888-007 .............................. Plate ........................................................................................................ 1 11 .................... 805888-011 .............................. Spring ..................................................................................................... 1 12 .................... 805888-003 .............................. Screw ...................................................................................................... 1 13 .................... 050008-053 .............................. Nut .......................................................................................................... 1 14 .................... 810204 ..................................... String Guard ............................................................................................ 2 15 .................... 050012-048 .............................. Retaining Ring ........................................................................................ 1 16 .................... 055002-022 .............................. Bearing Ball ............................................................................................. 1 17 .................... 050012-049 .............................. Retaining Ring ........................................................................................ 1 18 .................... 813189 ..................................... Flange ..................................................................................................... 1 19 .................... 050067-035 .............................. Screw ...................................................................................................... 3
805888-001 .............................. Caster Wheel Assembly (included 1 - 14) ............................................... 1 805230 ..................................... Caster Wheel Assembly (included 1, 3, 6 - 13) ....................................... 1 813128 ..................................... Wheel Assembly (included 4, 5, 14) ........................................................ 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-1.5-3130
17
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Printed in Germany
18M1.0-0000-00018
SECTION 2
Printed in Germany
19
TUBE/HOSE LAYOUT
Mounted in Power Unit by Battery Disconnect 28
1
28
to Lift Cylinder 6
15
Mounts to Power Unit
A
17
Part of Power Unit
24 22
15
2
to Lift Cylinder 25
Mounts to Power Unit
26 21 A 4
21 Fo
rk E
nd
23 20
3
5
11
Mounts Inside “B” B Reservoir 13
14
18
7
16 8
19 11 12 16
11
10
9
27
B 10 MP-3130-203 MP-2.1-3130
20M1.0-0000-00020
MP-ST3000-GB 10/04 • Printed in Germany
TUBE/HOSE LAYOUT INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 811628 ..................................... Plate ........................................................................................................ 1 050067-023 .............................. Screw ...................................................................................................... 2 2 ..................... 052081-002 .............................. Clamp ...................................................................................................... 1 3 ..................... 812905 ..................................... Pad .......................................................................................................... 1 4 ..................... 811845-001 .............................. Motor Assembly ...................................................................................... 1 811845-300 .............................. Motor Brush Kit ................................................................................. 1 811845-301 .............................. Motor Brush Holder & Brush Kit ........................................................ 1 811845-101 .............................. Headband .......................................................................................... 1 5 ..................... 811845-100 .............................. Motor Coupler ......................................................................................... 1 6 ..................... 811823 ..................................... Tube ........................................................................................................ 1 7 ..................... 809717 ..................................... Pump & Flange ....................................................................................... 1 8 ..................... 809700 ..................................... Check Valve ............................................................................................ 1 9 ..................... 805280 ..................................... Relief Valve ............................................................................................. 1 10 .................... 809771 ..................................... Flange Assembly .................................................................................... 1 050005-022 .............................. Screw ................................................................................................ 3 809719 ..................................... O-Ring ............................................................................................... 1 809720 ..................................... O-Ring ............................................................................................... 1 11 .................... 809702 ..................................... Reservoir Assembly ............................................................................... 1 811821 ..................................... Reservoir .......................................................................................... 1 809703 ..................................... Filler Cap ........................................................................................... 1 809731 ..................................... Separator Plate ................................................................................. 1 809732 ..................................... Screw ................................................................................................ 2 809733 ..................................... O-Ring ............................................................................................... 2 809734 ..................................... Washer .............................................................................................. 2 12 .................... 809704 ..................................... Clamp Assembly ..................................................................................... 1 050005-063 .............................. Screw ................................................................................................ 1 13 .................... 811436 ..................................... Plate ........................................................................................................ 1 050071-019 .............................. Screw ...................................................................................................... 2 14 .................... 809706 ..................................... Suction Line Assembly ........................................................................... 1 809723 ..................................... Collar ................................................................................................. 1 809724 ..................................... Filter .................................................................................................. 1 15 .................... 052075-004 .............................. Clamp ...................................................................................................... 1 812900 ..................................... Block ....................................................................................................... 1 050006-026 .............................. Screw ...................................................................................................... 1 050068-002 .............................. Nut .......................................................................................................... 1 16 .................... 809726 ..................................... Lowering Block Assembly ...................................................................... 1 809773 ..................................... Hollow Screw .................................................................................... 1 809727 ..................................... Seal Kit .............................................................................................. 1 064091-002 .............................. Plug ......................................................................................................... 1 17 .................... 064091-001 .............................. Plug (TL Mast) ........................................................................................ 1 064004-001 .............................. Plug (TT Mast) ........................................................................................ 1 18 .................... 809735 ..................................... Solenoid Valve Assembly ........................................................................ 1 809714 ..................................... Coil .................................................................................................... 1 19 .................... 054174-001 .............................. Plug ......................................................................................................... 1 20 .................... 812182 ..................................... Hose ....................................................................................................... 1 21 .................... 809707 ..................................... Proportional Speed Block Assembly ...................................................... 1 809721 ..................................... O-Ring ............................................................................................... 2 050005-003 .............................. Screw ................................................................................................ 4 22 .................... 811826 ..................................... Tube ........................................................................................................ 1 23 .................... 809729 ..................................... Proportional Valve Assembly .................................................................. 1 809730 ..................................... Coil .................................................................................................... 1 24 .................... 811977 ..................................... Cover ...................................................................................................... 1 050068-003 .............................. Nut .......................................................................................................... 1 25 .................... 064004-001 .............................. Fitting ...................................................................................................... 1 26 .................... 064091-002 .............................. Plug ......................................................................................................... 1 27 .................... 809766 ..................................... Flow Regulator ........................................................................................ 1 28 .................... 815250-001 .............................. Hydraulic Control Module ........................................................................ 1 050007-009 .............................. Screw ...................................................................................................... 2 0550059-001 ............................ Spacer .................................................................................................... 2
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-2.1-3130
21
HYDRAULIC TT MAST
7
5
6
4 5
10 9
8 9
8 9 11
3
Fo
rk E
nd
2 1
3 MP-3130-201
MP-2.8-3130
22M1.0-0000-00022
MP-ST3000-GB 10/04 • Printed in Germany
HYDRAULIC TT MAST INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ........................................................................ Tube (see Section 02.1) .......................................................................... 1 2 ..................... 064004-001 .............................. Fitting ...................................................................................................... 1 3 ..................... 064004-023 .............................. Fitting ...................................................................................................... 2 4 ..................... 813255 ..................................... Bracket ................................................................................................... 1 050067-023 .............................. Screw ...................................................................................................... 1 5 ..................... 054180-003 .............................. Fitting ...................................................................................................... 1 6 ..................... 811605-001 .............................. Tube (3900 mm & 4250 mm Lift Height) .................................................. 1 811605-002 .............................. Tube (4860 mm Lift Height) ..................................................................... 1 7 ..................... 811606-001 .............................. Hose (3900 mm & 4250 mm Lift Height) ................................................. 1 811606-002 .............................. Hose (4860 mm Lift Height) .................................................................... 1 8 ..................... 054180-003 .............................. Fitting ...................................................................................................... 1 9 ..................... 811603 ..................................... Bracket ................................................................................................... 1 050006-035 .............................. Screw ...................................................................................................... 2 050008-024 .............................. Nut .......................................................................................................... 2 10 .................... 811604 ..................................... Tube ........................................................................................................ 1 11 .................... 064004-001 .............................. Fitting ...................................................................................................... 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-2.8-3130
23
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Printed in Germany
24M1.0-0000-00024
SECTION 3
Printed in Germany
25
GEARBOX
Traction Motor see section 03.2 28
36 35
29
31 32 33 0
27
34
10Nm 17
30
35
1
26 22 23
24 19
25 4
21
5
18
6
9
20
7
0
8 2
10Nm 11
35
10 16
1 12 13
0
14 122 - 135Nm
38 0
15 37
25Nm
3
MP-3130-301 MP-3.1-3130
26M1.0-0000-00026
MP-ST3000-GB 10/04 • Printed in Germany
GEARBOX INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
0 ..................... 805844-002 .............................. Gearbox (without 37 & 38) ...................................................................... 1 1 ........................... 805115-004 .............................. Screw ................................................................................................ 2 2 ........................... 805112-006 .............................. Ring Retaining ................................................................................... 1 3 ........................... 805100 ..................................... Wheel Shaft ....................................................................................... 1 4 ........................... 805110-001 .............................. Seal ................................................................................................... 1 5 ........................... 805111-001 .............................. Bearing .............................................................................................. 1 6 ........................... 805112-001 .............................. Ring Retaining ................................................................................... 1 7 ........................... 805113-001 .............................. Bushing ............................................................................................. 1 8 ........................... 805111-002 .............................. Bearing .............................................................................................. 1 9 ........................... 805101 ..................................... Housing ............................................................................................. 1 10 .......................... 805102 ..................................... Gear .................................................................................................. 1 11 .......................... 805114-001 .............................. Shim .................................................................................................. AR 12 .......................... 805114-002 .............................. Shim .................................................................................................. AR 13 .......................... 805112-002 .............................. Ring Retaining ................................................................................... 1 14 .......................... 805235 ..................................... Gearbox Cover .................................................................................. 1 15 .......................... 805115-001 .............................. Screw ................................................................................................ 10 16 .......................... 805115-002 .............................. Screw ................................................................................................ 2 17 .......................... 805115-003 .............................. Screw ................................................................................................ 2 18 .......................... 805112-003 .............................. Ring Retaining ................................................................................... 1 19 .......................... 805116-001 .............................. Washer .............................................................................................. 1 20 .......................... 805104 ..................................... Gear .................................................................................................. 1 21 .......................... 805112-004 .............................. Ring Retaining ................................................................................... 1 22 .......................... 805111-003 .............................. Bearing .............................................................................................. 1 23 .......................... 805105 ..................................... Pinion ................................................................................................ 1 24 .......................... 805106 ..................................... Key .................................................................................................... 1 25 .......................... 805111-004 .............................. Bearing .............................................................................................. 1 26 .......................... 805107 ..................................... Cap .................................................................................................... 1 27 .......................... 805111-005 .............................. Bearing .............................................................................................. 1 28 .......................... 805116-002 .............................. Washer .............................................................................................. 1 29 .......................... 805117 ..................................... O-Ring ............................................................................................... 1 30 .......................... 805113-002 .............................. Bushing ............................................................................................. 1 31 .......................... 805110-002 .............................. Seal ................................................................................................... 1 32 .......................... 805118 ..................................... Ring ................................................................................................... 1 33 .......................... 805108 ..................................... Pinion ................................................................................................ 1 34 .......................... 805112-005 .............................. Ring Retaining ................................................................................... 1 35 .......................... 805110-003 .............................. Seal ................................................................................................... 3 36 .......................... 805109 ..................................... Breather ............................................................................................ 1 37 .................... 805808 ..................................... Drive Tyre (Vulkollan) .............................................................................. 1 811535 ..................................... Drive Tyre Assembly (Rubber ................................................................. 1 811536 ..................................... Tyre ................................................................................................... 1 811537 ..................................... Rim .................................................................................................... 1 38 .................... 050074-002 .............................. Screw ...................................................................................................... 4
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-3.1-3130
27
DRIVE MOTOR
3 1 4 2
9 5
10 6 7 8
12 11
21 21 19 20
18 20
13
17
Part of Motor Housing
14 15
16
23 22 MP-3130-302 MP-3.2-3130
28M1.0-0000-00028
MP-ST3000-GB 10/04 • Printed in Germany
DRIVE MOTOR INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
0 ..................... 812047 ..................................... Drive Motor ............................................................................................. 1 1 ........................... 809755 ..................................... Screw ................................................................................................ 2 2 ........................... 809756 ..................................... Washer .............................................................................................. 2 3 ........................... 809748 ..................................... G. - Commutator End Plate ............................................................... 1 809749 ..................................... Commutator End Plate ...................................................................... 1 4 ........................... 809760 ..................................... Coverband ......................................................................................... 1 5 ........................... 809759 ..................................... Circlip ................................................................................................ 1 6 ........................... 809754 ..................................... Bearing Ball ....................................................................................... 1 7 ........................... 809757 ..................................... Circlip ................................................................................................ 1 8 ........................... 809750 ..................................... Brush Plate ........................................................................................ 1 9 ........................... 809753 ..................................... Brushes ............................................................................................. 4 10 .......................... 809751 ..................................... Spring ................................................................................................ 4 11 .......................... 809752 ..................................... Screw ................................................................................................ 6 12 .......................... 809758 ..................................... Armature ........................................................................................... 1 13 .......................... 809743 ..................................... Field Coil Set ..................................................................................... 1 14 .......................... 809744 ..................................... Pole - Shoe ........................................................................................ 4 15 .......................... 809742 ..................................... Pin ..................................................................................................... 1 16 .......................... 809736 ..................................... Motor Housing ................................................................................... 1 17 .......................... 809745 ..................................... Screw ................................................................................................ 8 18 .......................... 809737 ..................................... Screw ................................................................................................ 4 19 .......................... 809738 ..................................... Isolation Disk .................................................................................... 8 809740 ..................................... Disk ................................................................................................... 16 20 .......................... 809741 ..................................... Washer .............................................................................................. 16 21 .......................... 809739 ..................................... Nut ..................................................................................................... 8 22 .......................... 809746 ..................................... Ring ................................................................................................... 1 23 .......................... 809747 ..................................... Screw ................................................................................................ 8
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-3.2-3130
29
KNUCKLE 11
10
13 8
12 7
ORS
BRS
7 5 4 2
6
3 14 15
16
1
Control Handle see section 04.5
16
15
0
14
86Nm 9
17
MP-3130-303
MP-3.3-3130
30M1.0-0000-00030
MP-ST3000-GB 10/04 • Printed in Germany
KNUCKLE INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 054011-006 .............................. Fitting ...................................................................................................... 1 2 ..................... 803013 ..................................... Spring ..................................................................................................... 3 3 ..................... 803353 ..................................... Spacer .................................................................................................... 1 4 ..................... 805760 ..................................... Shaft ........................................................................................................ 1 5 ..................... 050000-015 .............................. Roll Pin ................................................................................................... 1 6 ..................... 045215 ..................................... Knuckle ................................................................................................... 1 050009-021 .............................. Washer (0,5 mm) .................................................................................... AR 050009-022 .............................. Washer (1,0 mm) .................................................................................... AR 050009-023 .............................. Washer (1,5 mm) .................................................................................... AR 7 ..................... 805859 ..................................... Switch (BRS & ORS) .............................................................................. 2 803310 ..................................... Actuator .................................................................................................. 2 8 ..................... 050004-032 .............................. Screw ...................................................................................................... 4 9 ..................... 050005-037 .............................. Screw ...................................................................................................... 4 10 .................... 805738 ..................................... Damper Sheet ......................................................................................... 1 11 .................... 050003-010 .............................. Screw ...................................................................................................... 2 12 .................... 050005-032 .............................. Screw ...................................................................................................... 6 13 .................... 045234 ..................................... Cable Protection ..................................................................................... 1 14 .................... 045317 ..................................... Seal Metallic ............................................................................................ 2 15 .................... 045319 ..................................... Bearing ................................................................................................... 2 16 .................... 045318 ..................................... Bearing Outer Race ................................................................................ 2 17 .................... 813183 ..................................... Flange ..................................................................................................... 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-3.3-3130
31
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Printed in Germany
32M1.0-0000-00032
SECTION 4
Printed in Germany
33
ELECTRICAL PARTS
M1610 MP-4.0-3130
34M1.0-0000-00034
MP-ST3000-GB 10/04 • Printed in Germany
ELECTRICAL PARTS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 803450-001 .............................. Socket Housing 2 way ............................................................................ AR 803450-002 .............................. Socket Housing 4 way ............................................................................ AR 803450-003 .............................. Socket Housing 6 way ............................................................................ AR 803450-004 .............................. Socket Housing 8 way ............................................................................ AR 803450-014 .............................. Socket Housing 16 way .......................................................................... AR 2 ..................... 803450-010 .............................. Socket Insert AWG 18 ............................................................................ AR 803450-011 .............................. Socket Insert AWG 24 ............................................................................ AR 3 ..................... 803450-005 .............................. Socket Housing 2 way ............................................................................ AR 803450-006 .............................. Socket Housing 4 way ............................................................................ AR 803450-007 .............................. Socket Housing 6 way ............................................................................ AR 803450-008 .............................. Socket Housing 8 way ............................................................................ AR 803450-015 .............................. Socket Housing 10 way .......................................................................... AR 803450-009 .............................. Socket Housing 12 way .......................................................................... AR 116851 ..................................... Socket Housing 16 way .......................................................................... AR 803450-013 .............................. Socket Housing 24 way .......................................................................... AR 4 ..................... 116858 ..................................... Socket Insert AWG 18 ............................................................................ AR 803450-012 .............................. Socket Insert AWG 24 ............................................................................ AR 5 ..................... 803450-016 .............................. Socket Housing 3 way ............................................................................ AR 803450-017 .............................. Socket Housing 6 way ............................................................................ AR 803450-018 .............................. Socket Housing 8 way ............................................................................ AR 6 ..................... 803450-013 .............................. Socket Insert AWG 18 ............................................................................ AR TOOLS (not shown) 117615 ..................................... Extaction ................................................................................................. 1 117636 ..................................... Crimping .................................................................................................. 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.0-3130
35
ELECTRICAL PARTS
29
25
29 22
29
26
25 29 27
23
24
28 21
14 11
23
12 1
22 3
13
15 16 17 18
5 4
FU2 19
10
18 16
2 18 20 8
6
18 16
7 9
MP-3130-401 MP-4.0-3130
36M1.0-0000-00036
MP-ST3000-GB 10/04 • Printed in Germany
ELECTRICAL PARTS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 811396 ..................................... Electrical Panel ....................................................................................... 1 2 ..................... 050067-012 .............................. Screw ...................................................................................................... 3 3 ..................... 065004-024 .............................. Grommet ................................................................................................. 1 4 ..................... 813096-001 .............................. Controller ................................................................................................ 1 053051-008 .............................. Heat Paste .............................................................................................. AR 5 ..................... 050025-015 .............................. Screw ...................................................................................................... 4 6 ..................... 050068-001 .............................. Nut .......................................................................................................... 4 7 ..................... 078708-002 .............................. Horn ........................................................................................................ 1 8 ..................... 050073-003 .............................. Spring Nut ............................................................................................... 1 9 ..................... 050068-003 .............................. Nut .......................................................................................................... 1 10 .................... 050025-008 .............................. Screw ...................................................................................................... 1 11 .................... 812911 ..................................... Holder ..................................................................................................... 1 12 .................... 805824 ..................................... Fuse Holder ............................................................................................ 2 13 .................... 050005-006 .............................. Screw ...................................................................................................... 4 14 .................... 050068-001 .............................. Nut .......................................................................................................... 4 15 .................... 050009-016 .............................. Washer ................................................................................................... 3 16 .................... 050008-051 .............................. Nut .......................................................................................................... 8 17 .................... 812284 ..................................... Buss Bar ................................................................................................. 1 18 .................... 054152-003 .............................. Copper Washer ....................................................................................... 8 19 .................... 802816-005 .............................. Fuse (125A) ............................................................................................ 1 20 .................... 802816-007 .............................. Fuse (100 A) ........................................................................................... 1 21 .................... 813090 ..................................... Plate ........................................................................................................ 1 22 .................... 050067-034 .............................. Screw ...................................................................................................... 2 23 .................... 050068-004 .............................. Nut .......................................................................................................... 2 24 .................... 812166 ..................................... Bracket (SBE 160) .................................................................................. 1 814976 ..................................... Bracket (DIN 80) ..................................................................................... 1 25 .................... 811649-002 .............................. Connector Assembly (SBE 160) ............................................................. 1 814401-003 .............................. Battery Housing (SBE 160) ............................................................... 1 052051-032 .............................. Power Cable + (SBE 160) ................................................................ 1 052051-033 .............................. Power Cable - (SBE 160) ................................................................. 1 811571-004 .............................. Connector Assembly (DIN 80) ................................................................ 1 813241-022 .............................. Battery Housing (DIN 80) .................................................................. 1 052051-034 .............................. Power Cable + (DIN 80) .................................................................. 1 052051-035 .............................. Power Cable - (DIN 80) ................................................................... 1 26 .................... 050007-011 .............................. Screw ...................................................................................................... 2 050007-012 .............................. Screw (DIN 80) ....................................................................................... 2 050006-024 .............................. Screw (DIN 80) ....................................................................................... 4 050009-014 .............................. Washer (DIN 80) ..................................................................................... 8 27 .................... 050008-015 .............................. Nut .......................................................................................................... 2 050068-002 .............................. Nut (DIN 80) ............................................................................................ 2 28 .................... 050068-002 .............................. Nut .......................................................................................................... 2 29 .................... 805856-001 .............................. Emergency Disconnector Assembly (SBE 160) ..................................... 1 045239-001-01 ......................... Emergency Disconnector (SBE 160) ................................................ 1 050005-012 .............................. Screw (SBE 160) .............................................................................. 4 050068-002 .............................. Nut (SBE 160) ................................................................................... 4 805856-004 .............................. Emergency Disconnector Assembly (DIN 80) ........................................ 1 045239-001-02 ......................... Emergency Disconnector (DIN 80) ................................................... 1 050006-024 .............................. Screw (DIN 80) ................................................................................. 2 050007-010 .............................. Screw (DIN 80) ................................................................................. 2 050068-002 .............................. Nut (DIN 80) ...................................................................................... 4 811557 ..................................... Plate (DIN 80) ................................................................................... 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.0-3130
37
ELECTRICAL PARTS
15 14
14 16 15
14
15
16
2
16
16
16
DB 1
15
10
4 3 10
9 9 7
6
13 5
11 8
13
Contactors see Section 04.4
12
MP-3130-402 MP-4.0-3130
38M1.0-0000-00038
MP-ST3000-GB 10/04 • Printed in Germany
ELECTRICAL PARTS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 062009-004 .............................. Termonal Block ....................................................................................... 1 2 ..................... 050005-003 .............................. Screw ...................................................................................................... 2 050004-014 .............................. Screw ...................................................................................................... 2 3 ..................... 050009-004 .............................. Washer ................................................................................................... 2 4 ..................... 050008-001 .............................. Nut .......................................................................................................... 2 5 ..................... 811397 ..................................... Bracket ................................................................................................... 1 6 ..................... 050073-003 .............................. Spring Nut ............................................................................................... 2 7 ..................... 050025-008 .............................. Screw ...................................................................................................... 2 8 ..................... 050068-003 .............................. Nut .......................................................................................................... 2 9 ..................... 050009-004 .............................. Washer ................................................................................................... 4 10 .................... 050004-038 .............................. Screw ...................................................................................................... 4 11 .................... 812285 ..................................... Buss Bar ................................................................................................. 1 12 .................... 812286 ..................................... Buss Bar ................................................................................................. 1 13 .................... 802820 ..................................... Contactor ................................................................................................ 2 14 .................... 812350 ..................................... Bracket ................................................................................................... 1 050025-017 .............................. Screw ...................................................................................................... 1 050068-005 .............................. Nut .......................................................................................................... 1 15 .................... 803208 ..................................... Leaf Spring .............................................................................................. 1 050006-008 .............................. Screw ...................................................................................................... 2 050008-008 .............................. Nut .......................................................................................................... 2 16 .................... 803619-002 .............................. Limit Switch (LMS) .................................................................................. 1 050004-032 .............................. Screw ...................................................................................................... 2 050008-004 .............................. Nut .......................................................................................................... 2
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.0-3130
39
CONTACTOR
MP-3130-404 MP-4.4-3130
40M1.0-0000-00040
MP-ST3000-GB 10/04 • Printed in Germany
CONTACTOR INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
0 ..................... 802820 ..................................... Contactor ................................................................................................ 2 1 ........................... 803689 ..................................... Contact Fixed .................................................................................... 2 2 ........................... 803690 ..................................... Contact Movable ............................................................................... 1 3 ........................... 803691 ..................................... Frame & Coil 24V .............................................................................. 1 4 ........................... 803692-001 .............................. Spring ................................................................................................ 1 5 ........................... 803693 ..................................... Cover ................................................................................................ 1 6 ........................... 803694 ..................................... Screw ................................................................................................ 2 128939 ..................................... Diode Assembly (only for Pump Contactor) ...................................... 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.4-3130
41
CONTROL HANDLE 4 19 3
18
16 18
11
HNS2 15
17 12 17 14 16 9
8 6
8 8
HNS1 13
7 4
14 8 6 8 7 12
4 10
Fo
rk
5
En
d
1
2
2
MP-3130-405 MP-4.5-3130
42M1.0-0000-00042
MP-ST3000-GB 10/04 • Printed in Germany
CONTROL HANDLE INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
0 ..................... 811913-006-01 ......................... Control Handle Assembly ....................................................................... 1 1 ........................... 808799 ..................................... Tiller .................................................................................................. 1 2 ........................... 051058-001 .............................. Bushing ............................................................................................. 2 3 ........................... 812298 ..................................... Tiller Harness .................................................................................... 1 4 ........................... 812894-002 .............................. Screw ................................................................................................ 1 5 ........................... 808986 ..................................... Lower Shell ........................................................................................ 1 6 ........................... 792940 ..................................... U-Nut Retainer .................................................................................. 2 7 ........................... 812893-003 .............................. Screw ................................................................................................ 2 8 ........................... 812893-001 .............................. Screw ................................................................................................ 6 9 ........................... 808985 ..................................... Upper Shell ........................................................................................ 1 10 .......................... 808987-001 .............................. Handgrip ............................................................................................ 1 11 .......................... 808987-002 .............................. Handgrip ............................................................................................ 1 12 .......................... 812894-005 .............................. Screw ................................................................................................ 2 13 .......................... 811932-001 .............................. Horn Switch HNS1 ............................................................................ 1 14 .......................... 810336 ..................................... Plug ................................................................................................... 2 15 .......................... 811932-002 .............................. Horn Switch HNS2 ............................................................................ 1 16 .......................... 814286 ..................................... Nut ..................................................................................................... 2 17 .......................... 814287 ..................................... Washer .............................................................................................. 2 18 .......................... 812893-004 .............................. Screw ................................................................................................ 2 19 .......................... 811949-003 .............................. Contorl Handle Cap (see next Page) ................................................. 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.5-3130
43
CONTROL HANDLE
2 2 32
23
26 27
1 28 POT, FS, RS
30
29
31 25
26
24
20 27
19
24
10 9
22
23 21
Fo
rk
En
14
d
8
SAS 5
33
9 9
7 9 6
15
18
16 34
18
HSS
11
13
17
9
3
RAS LOS1 12
LOS2
9
4
MP-3130-406
MP-4.5-3130
44M1.0-0000-00044
MP-ST3000-GB 10/04 • Printed in Germany
CONTROL HANDLE INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
0 ..................... 811949-003 .............................. Control Handle Cap Assembly ................................................................ 1 1 ........................... 808951-001 .............................. Switch Cover ..................................................................................... 1 2 ........................... 812893-002 .............................. Screw ................................................................................................ 2 3 ........................... 810328 ..................................... Support ............................................................................................. 1 4 ........................... 812894-002 .............................. Screw ................................................................................................ 2 5 ........................... 811935 ..................................... Micro-Switch SAS ............................................................................. 1 6 ........................... 803469-018 .............................. Screw ................................................................................................ 2 7 ........................... 051057-026 .............................. Spring ................................................................................................ 4 8 ........................... 811936 ..................................... Button Bridge ..................................................................................... 1 9 ........................... 803469-017 .............................. Screw ................................................................................................ 11 10 .......................... 808992 ..................................... Button ................................................................................................ 1 11 .......................... 812941 ..................................... Main PC Board .................................................................................. 1 12 .......................... 812942-002 .............................. Hydraulic PC Board, Includes RAS, LOS1 & LOS2 .......................... 1 13 .......................... 811941 ..................................... Fast/Slow Switch HSS ...................................................................... 1 14 .......................... 808990 ..................................... Lower Cover ...................................................................................... 1 15 .......................... 810332 ..................................... Support ............................................................................................. 1 16 .......................... 051057-021 .............................. Spring ................................................................................................ 1 17 .......................... 811940 ..................................... Shaft .................................................................................................. 1 18 .......................... 050012-075 .............................. Retaining Ring ................................................................................... 2 19 .......................... 810331 ..................................... Support ............................................................................................. 1 20 .......................... 811939 ..................................... Shaft .................................................................................................. 1 21 .......................... 808989 ..................................... Lift Cover ........................................................................................... 1 22 .......................... 051057-023 .............................. Spring ................................................................................................ 1 23 .......................... 812894-004 .............................. Screw ................................................................................................ 2 24 .......................... 803469-023 .............................. Screw ................................................................................................ 2 25 .......................... 808993-001 .............................. Thumbwheel LH ................................................................................ 1 26 .......................... 050012-076 .............................. Retaining Ring ................................................................................... 2 27 .......................... 810335 ..................................... Bushing ............................................................................................. 2 28 .......................... 813533 ..................................... Traction Potentiometer POT ............................................................... 1 29 .......................... 810333 ..................................... Spring Activator ................................................................................. 1 30 .......................... 811937 ..................................... Shaft .................................................................................................. 1 31 .......................... 812884 ..................................... Spring ................................................................................................ 1 32 .......................... 808993-002 .............................. Thumbwheel RH ................................................................................ 1 33 .......................... 051057-028 .............................. Spring ................................................................................................ 1 34 .......................... 051057-022 .............................. Spring ................................................................................................ 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.5-3130
45
CHARGER
1
2 3 4
A 10 5
9
6 8
11 A 7
12
MP-3130-407
MP-4.8-3130
46M1.0-0000-00046
MP-ST3000-GB 10/04 • Printed in Germany
CHARGER INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 810695 ..................................... Charger ................................................................................................... 1 2 ..................... 050006-027 .............................. Screw ...................................................................................................... 4 3 ..................... 050073-002 .............................. Spring Nut ............................................................................................... 4 4 ..................... 050008-015 .............................. Nut .......................................................................................................... 4 5 ........................................................................ Instrument Panel (see Section 4.9) ......................................................... 1 6 ..................... 808859 ..................................... Main Supply Connection ......................................................................... 1 7 ..................... 805843 ..................................... Plug (only UK) ........................................................................................ 1 8 ..................... 050005-059 .............................. Screw ...................................................................................................... 2 9 ..................... 805876 ..................................... Bracket ................................................................................................... 1 10 .................... 050008-015 .............................. Nut .......................................................................................................... 2 11 .................... 050005-062 .............................. Screw ...................................................................................................... 2 12 .................... 805825-002 .............................. Blind Rivet Nut ........................................................................................ 2
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.8-3130
47
BATTERIES 9 8 10 8 10 9 9
10
7
3
7
9
3
7 6 10
5
4
2
1 3
Power Unit
MP-3130-413
MP-4.8-3130
48M1.0-0000-00048
MP-ST3000-GB 10/04 • Printed in Germany
BATTERIES INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 050025-017 .............................. Screw ...................................................................................................... 1 2 ..................... 050068-005 .............................. Nut .......................................................................................................... 1 3 ........................................................................ Batteries (195 Ah) ................................................................................... 4 Batteries (95 Ah) ..................................................................................... 2 4 ..................... 811444 ..................................... Bracket ................................................................................................... 1 5 ..................... 050067-023 .............................. Screw ...................................................................................................... 2 6 ..................... 055054 ..................................... Sleeve ..................................................................................................... 2 7 ..................... 052051-040 .............................. Power Cable ............................................................................................ 3 8 ..................... 811649-102 .............................. Battery Cable & Connector (195Ah - SBE160) ....................................... 1 814401-003 .............................. Connector (195Ah - SBE160) ........................................................... 1 811649-202 .............................. Battery Cable & Connector (95Ah - SBE160) ......................................... 1 814401-003 .............................. Connector (195Ah - SBE160) ........................................................... 1 811649-104 .............................. Battery Cable & Connector (195Ah - DIN80A) ....................................... 1 813241-012 .............................. Connector (195Ah - DIN80A) ............................................................ 1 811649-204 .............................. Battery Cable & Connector (95Ah - DIN80A) ......................................... 1 813241-012 .............................. Connector (195Ah - DIN80A) ............................................................ 1 9 ..................... 125958-001 .............................. Boot (red) ................................................................................................ AR 10 .................... 125958-002 .............................. Boot (black) ............................................................................................. AR
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.8-3130
49
INSTRUMENT
3
2 4 5 KYS
5 KYS
1 9
14 13
15 11 3
10 4 8
12 7
6
MP-3130-411 MP-4.9-3130
50M1.0-0000-00050
MP-ST3000-GB 10/04 • Printed in Germany
INSTRUMENT INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 813199 ..................................... Bracket ................................................................................................... 1 2 ..................... 050073-002 .............................. Nut Spring ............................................................................................... 2 3 ..................... 050025-004 .............................. Screw ...................................................................................................... 4 4 ..................... 050068-002 .............................. Nut .......................................................................................................... 4 5 ..................... 072708 ..................................... Switch Key (KYS - included 2 Keys, Ring and Nut) ................................ 1 107151-001 .............................. Key .......................................................................................................... 1 803678-012 .............................. Tabs Terminal .......................................................................................... 2 6 ..................... 802833 ..................................... Combi Instrument .................................................................................... 1 7 ..................... 805771 ..................................... Clip .......................................................................................................... 1 8 ..................... 805752 ..................................... Fuse Holder ............................................................................................ 1 805751-001 .............................. Fuse 10A ................................................................................................ 1 9 ..................... 814971 ..................................... Plug Holder ............................................................................................. 1 10 .................... 050004-012 .............................. Screw ...................................................................................................... 4 11 .................... 050008-001 .............................. Nut .......................................................................................................... 4 12 ....................................................................... Plug (see Section 4.8) ............................................................................ 1 13 .................... 050005-059 .............................. Screw ...................................................................................................... 2 14 .................... 050008-015 .............................. Nut .......................................................................................................... 2 15 .................... 814554 ..................................... Bracket ................................................................................................... 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.9-3130
51
REVERSE ALARM
Electrical Components see Section 4.0 5 4 5 4 7
1
2 2
Power Unit 8 6 3
MP-3130-403 MP-4.10-3130
52M1.0-0000-00052
MP-ST3000-GB 10/04 • Printed in Germany
REVERSE ALARM INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 115565 ..................................... Alarm ....................................................................................................... 1 2 ..................... 050073-002 .............................. Spring Nut ............................................................................................... 2 3 ..................... 050025-003 .............................. Screw ...................................................................................................... 2 4 ..................... 050009-013 .............................. Washer ................................................................................................... 2 5 ..................... 050008-018 .............................. Nut .......................................................................................................... 2 6 ..................... 814633 ..................................... Driver Module .......................................................................................... 1 7 ..................... 050008-008 .............................. Nut .......................................................................................................... 1 8 ..................... 050006-008 .............................. Screw ...................................................................................................... 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.10-3130
53
STROBE LIGHT
7 FLS 8
9 6
9
Fo
rk
10 En
d
5 4 4
Outer Mast Top Brace
1
3 3 Power Unit
2
MP-3130-412
MP-4.10-3130
54M1.0-0000-00054
MP-ST3000-GB 10/04 • Printed in Germany
STROBE LIGHT INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 062693 ..................................... Power Supply .......................................................................................... 1 2 ..................... 050025-015 .............................. Screw ...................................................................................................... 2 3 ..................... 050073-001 .............................. Spring Nut ............................................................................................... 2 4 ..................... 050009-007 .............................. Washer ................................................................................................... 2 5 ..................... 050008-010 .............................. Nut .......................................................................................................... 2 6 ..................... 130988 ..................................... Bracket ................................................................................................... 1 7 ..................... 060062-006 .............................. Screw ...................................................................................................... 2 8 ..................... 125616-001 .............................. Strobe Light Assembly (Amber) .............................................................. 1 9 ..................... 076901-002 .............................. Spacer .................................................................................................... 2 10 .................... 060013-043 .............................. Screw ...................................................................................................... 2
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-4.10-3130
55
Page intentionally left blank
Printed in Germany
56M1.0-0000-00056
SECTION 5
Printed in Germany
57
BRAKE
1
2
2
3
4 1 5 2 2
6
2 2 7
8
9
MP-3130-501 MP-5.6-3130
58M1.0-0000-00058
MP-ST3000-GB 10/04 • Printed in Germany
BRAKE INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
0 ..................... 807102 ..................................... Brake Assembly 24V .............................................................................. 1 1 ........................... 805119 ..................................... Pressure Block Adjusting Nut ........................................................... 1 2 ........................... 805120 ..................................... Hardware Kit ..................................................................................... 1 3 ........................... 805121 ..................................... Magnet Assembly ............................................................................. 1 4 ........................... 805122 ..................................... Retaining Ring ................................................................................... 1 5 ........................... 805123 ..................................... Hub .................................................................................................... 1 6 ........................... 805124 ..................................... Rotor Plate ........................................................................................ 1 7 ........................... 807105 ..................................... Rotor ................................................................................................. 1 8 ........................... 805125 ..................................... Protection Ring .................................................................................. 1 9 ........................... 807104 ..................................... Friction Plate ..................................................................................... 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-5.6-3130
59
Page intentionally left blank
Printed in Germany
60M1.0-0000-00060
SECTION 7
Printed in Germany
61
TL MAST
3
4 5
8 9
10 11
7
5 3
12
14
6 16
4
10 11 15
16 12
17 15 18
1
13
Torque Bolts 385 Nm 23
0
rk Fo
20
En
d
19 16 15 22
Mast Lift Cylinder see Section 08.1
16 15
2
Power Unit see Section 01.0
23
21
MP-3130-701
MP-7.1-3130
62M1.0-0000-00062
MP-ST3000-GB 10/04 • Printed in Germany
TL MAST INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 811904-*** ............................... Inner Mast (see Table) ............................................................................ 1 2 ..................... 812917-*** ............................... Outer Mast (see Table) ........................................................................... 1 3 ..................... 811114 ..................................... Chain Pulley ............................................................................................ 2 4 ..................... 050009-031 .............................. Washer ................................................................................................... 2 5 ..................... 050012-006 .............................. Retaining Ring ........................................................................................ 2 6 ..................... 812145 ..................................... Cover ...................................................................................................... 1 7 ..................... 050067-043 .............................. Screw ...................................................................................................... 1 8 ..................... 812144 ..................................... Cover ...................................................................................................... 1 9 ..................... 050067-023 .............................. Screw ...................................................................................................... 1 10 .................... 050012-078 .............................. Retaining Ring ........................................................................................ 2 11 .................... 813254 ..................................... Shim ........................................................................................................ AR 12 .................... 813236-001 .............................. Elasto Assembly ..................................................................................... 2 13 .................... 811247-002 .............................. Bracket ................................................................................................... 1 14 .................... 811247-001 .............................. Bracket ................................................................................................... 1 15 .................... 810691 ..................................... Roller ...................................................................................................... 4 16 .................... 803915-001 .............................. Shim (0.5 mm) ......................................................................................... AR 803915-002 .............................. Shim (1.0 mm) ......................................................................................... AR 803915-003 .............................. Shim (1.5 mm) ......................................................................................... AR 17 .................... 050068-003 .............................. Nut .......................................................................................................... 4 18 .................... 050005-076 .............................. Screw ...................................................................................................... 4 19 .................... 813420 ..................................... Carriage Bolt ........................................................................................... 6 20 .................... 050008-070 .............................. Nut .......................................................................................................... 6 21 .................... 811729-001 .............................. Cylinder Cover ........................................................................................ 1 22 .................... 811729-002 .............................. Cylinder Cover ........................................................................................ 1 23 .................... 050003-032 .............................. Screw ...................................................................................................... 4
Lift Height
Position 1
Position 2
2400 mm
811904-005
812917-101
2820 mm
811904-006
812917-102
3220 mm
811904-002
812917-002
3700 mm
811904-008
812917-104
4200 mm
811904-009
812917-105 Tab009gb
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.1-3130
63
TL MAST - CHAIN
6 3 1
6
3
3
2
6
1 2
6
2
3 2
4 4
3
5 5
Fork Carriage see Section 07.7
TL Mast see Section 07.1
MP-3130-706
MP-7.2-3130
64M1.0-0000-00064
MP-ST3000-GB 10/04 • Printed in Germany
TL MAST - CHAIN INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 802766 ..................................... Chain Tensioner ...................................................................................... 2 2 ..................... 812046 ..................................... Chain Pin ................................................................................................ 4 3 ..................... 050001-013 .............................. Cotter Pin ................................................................................................ 8 4 ..................... 050008-052 .............................. Nut .......................................................................................................... 4 5 ..................... 050001-023 .............................. Cotter Pin ................................................................................................ 2 6 ..................... 051061-*** ............................... Chain (see Table) .................................................................................... 2
Lift Height
Position 6
2400 mm
051061-015
2820 mm
051061-019
3220 mm
051061-007
3700 mm
051061-020
4200 mm
051061-005 Tab010gb
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.2-3130
65
TT MAST
5
31
Free Lift Cylinder see Section 08.3
6 28 8
9 10 27 4
7
12 27 13
11 5
23 6 27
4 30
18 17
27
1
16
15
30 14 24
29 19
27 4
27 26
2
27
22 4
4
27
21
F
Mast Lift Cylinder see Section 08.1
ork
En
d
4
22 3 0
25
Torque Bolts 385 Nm
20
Power Unit see Section 01.0
MP-3130-702
MP-7.5-3130
66M1.0-0000-00066
MP-ST3000-GB 10/04 • Printed in Germany
TT MAST INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 811046-*** ............................... Inner Mast (see Table) ............................................................................ 1 2 ..................... 811538-*** ............................... Middle Mast (see Table) .......................................................................... 1 3 ..................... 812218-*** ............................... Outer Mast (see Table) ........................................................................... 1 4 ..................... 810691 ..................................... Roller ...................................................................................................... 8 5 ..................... 811114 ..................................... Chain Pulley ............................................................................................ 2 6 ..................... 050012-006 .............................. Retaining Ring ........................................................................................ 3 7 ..................... 811602 ..................................... Shaft ........................................................................................................ 1 8 ..................... 050009-020 .............................. Washer ................................................................................................... 3 9 ..................... 811656 ..................................... Cover ...................................................................................................... 1 10 .................... 050067-025 .............................. Screw ...................................................................................................... 1 11 .................... 050009-031 .............................. Washer ................................................................................................... 1 12 .................... 812145 ..................................... Cover ...................................................................................................... 1 13 .................... 050067-043 .............................. Screw ...................................................................................................... 1 14 .................... 811247-002 .............................. Bracket ................................................................................................... 1 15 .................... 811247-001 .............................. Bracket ................................................................................................... 1 16 .................... 813236-001 .............................. Elasto Assembly ..................................................................................... 2 17 .................... 813254 ..................................... Shim ........................................................................................................ AR 18 .................... 050012-078 .............................. Retaining Ring ........................................................................................ 2 19 .................... 813256 ..................................... Screw ...................................................................................................... 2 20 .................... 811729-001 .............................. Cover ...................................................................................................... 1 21 .................... 811729-002 .............................. Cover ...................................................................................................... 1 22 .................... 050003-032 .............................. Screw ...................................................................................................... 4 23 .................... 050068-003 .............................. Nut .......................................................................................................... 4 24 .................... 050005-076 .............................. Screw ...................................................................................................... 4 25 .................... 813420 ..................................... Screw ...................................................................................................... 6 26 .................... 050008-070 .............................. Nut .......................................................................................................... 6 27 .................... 803915-001 .............................. Shim (0.5 mm) ......................................................................................... AR 803915-002 .............................. Shim (1.0 mm) ......................................................................................... AR 803915-003 .............................. Shim (1.5 mm) ......................................................................................... AR 28 .................... 803866 ..................................... Hose Pulley ............................................................................................. 1 29 .................... 050067-034 .............................. Screw ...................................................................................................... 2 30 .................... 811812 ..................................... Shim ........................................................................................................ 2 31 .................... 050000-068 .............................. Roll Pin ................................................................................................... 1
Lift Height
Position 1
Position 2
Position 3
3900 mm
811046-001
811538-001
812218-001
4250 mm
811046-001
811538-001
812218-001 Tab002gb
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.5-3130
67
TT MAST - CHAIN
Yoke see Section 07.11
3
9 3
2
8
1 3 3
** 4
1 5 2
3 2 2 6
4
7
3 5
5
see Fork Carriage Section 07.7
see TT Mast Section 07.5
MP-3130-707 MP-7.6-3130
68M1.0-0000-00068
MP-ST3000-GB 10/04 • Printed in Germany
TT MAST - CHAIN INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 802766 ..................................... Chain Tensioner ...................................................................................... 3 2 ..................... 812046 ..................................... Chain Pin ................................................................................................ 6 3 ..................... 050001-013 .............................. Cotter Pin ................................................................................................ 12 4 ..................... 050008-052 .............................. Nut .......................................................................................................... 6 5 ..................... 050001-023 .............................. Cotter Pin ................................................................................................ 4 6 ..................... 811793 ..................................... Chain Tensioner ...................................................................................... 1 7 ..................... 050008-048 .............................. Nut .......................................................................................................... 2 8 ..................... 051061-*** ............................... Chain (see Table) .................................................................................... 2 9 ..................... 051061-*** ............................... Chain (see Table) .................................................................................... 1
Lift Height
Position 8
Position 9
3900 mm
051061-009
051061-008
4250 mm
051061-009
051061-008 Tab003gb
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.6-3130
69
FORK CARRIAGE
3 2
1
4
6
7
5
MP-3130-703 MP-7.7-3130
70M1.0-0000-00070
MP-ST3000-GB 10/04 • Printed in Germany
FORK CARRIAGE INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 811348 ..................................... Fork Carriage TL ..................................................................................... 1 814883 ..................................... Fork Carriage TT ..................................................................................... 1 2 ..................... 803915-001 .............................. Shim (0.5 mm) ......................................................................................... AR 803915-002 .............................. Shim (1.0 mm) ......................................................................................... AR 803915-003 .............................. Shim (1.5 mm) ......................................................................................... AR 3 ..................... 810691 ..................................... Roller ...................................................................................................... 4 4 ..................... 050005-038 .............................. Screw ...................................................................................................... 1 5 ..................... 050005-023 .............................. Screw ...................................................................................................... 1 6 ..................... 803914 ..................................... Washer (without Load Backrest) ............................................................. 2 7 ..................... 050067-044 .............................. Screw (without Load Backrest) ............................................................... 2
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.7-3130
71
MAST SAFTY SCREEN
4
2 3 Outer Mast See Sections 07.1 & 07.5
1
MP-3130-708 MP-7.7-3130
72M1.0-0000-00072
MP-ST3000-GB 10/04 • Printed in Germany
MAST SAFETY SCREEN INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 812099-*** ............................... Plexiglas Guard ...................................................................................... 1 2 ..................... 050009-054 .............................. Washer ................................................................................................... 6 3 ..................... 050080-001 .............................. Nut .......................................................................................................... 6 4 ..................... 814211 ..................................... Shim ........................................................................................................ 6
Lift Height
Position 1
Mast
2400 mm
812099-005
TL
2820 mm
812099-006
TL
3220 mm
812099-002
TL
3700 mm
812099-007
TL
3900 mm
812099-003
TT
4200 mm
812099-008
TL
4250 mm
812099-003
TT Tab004gb
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.7-3130
73
FORKS
2
3 4
1 5
MP-3130-710 MP-7.9-3130
74M1.0-0000-00074
MP-ST3000-GB 10/04 • Printed in Germany
FORKS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 043168-002 .............................. Forks (914 mm) ...................................................................................... 2 043168-003 .............................. Forks (1067 mm) .................................................................................... 2 043168-004 .............................. Forks (1143 mm) .................................................................................... 2 043168-005 .............................. Forks (1219 mm) .................................................................................... 2 2 ..................... 043170 ..................................... Handle .................................................................................................... 2 3 ..................... 060000-075 .............................. Pin ........................................................................................................... 2 4 ..................... 043171 ..................................... Spring ..................................................................................................... 2 5 ..................... 043173 ..................................... Detent ..................................................................................................... 2
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.9-3130
75
LOAD BACKREST
1
2
MP-3130-709 MP-7.10-3130
76M1.0-0000-00076
MP-ST3000-GB 10/04 • Printed in Germany
LOAD BACKREST INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 803596 ..................................... Load Backrest ......................................................................................... 1 2 ..................... 050067-044 .............................. Screw ...................................................................................................... 4
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.10-3130
77
YOKE
5 1
6 4 5
3
2 3
see Section 8.3
MP-3130-705 MP-7.11-3130
78M1.0-0000-00078
MP-ST3000-GB 10/04 • Printed in Germany
YOKE INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 811463 ..................................... Yoke ........................................................................................................ 1 2 ..................... 810669 ..................................... Chain Pulley ............................................................................................ 1 3 ..................... 811468 ..................................... Spacer .................................................................................................... 2 4 ..................... 811467 ..................................... Pin ........................................................................................................... 1 5 ..................... 050012-009 .............................. Retaining Ring ........................................................................................ 2 6 ..................... 050012-006 .............................. Retaining Ring ........................................................................................ 1
811470 ..................................... Yoke Assembly ....................................................................................... 1
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-7.11-3130
79
Page intentionally left blank
Printed in Germany
80M1.0-0000-00080
SECTION 8
Printed in Germany
81
LIFT CYLINDER Mast TL/TT 1 2 3
9
1 10 5
4
2
5
3
6
4
7
11
6 7
12
8 8
9
12
10 11
13 13
MP-3130-801 MP-8.1-3130
82M1.0-0000-00082
MP-ST3000-GB 10/04 • Printed in Germany
LIFT CYLINDER INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
0 ..................... 811310-*** ............................... Cylinder Assembly (without 13/see Table) .............................................. 2 1 ........................... 814661 ..................................... Wiper ................................................................................................. 2 2 ........................... 807356 ..................................... Seal ................................................................................................... 2 3 ........................... 810646 ..................................... Guide Ring ........................................................................................ 2 4 ........................... 054172 ..................................... Bleed Screw ...................................................................................... 2 054173 ..................................... Seal ................................................................................................... 2 5 ........................... 810639 ..................................... Cap .................................................................................................... 2 6 ........................... 810644 ..................................... Backring ............................................................................................ 2 7 ........................... 811811 ..................................... O-Ring ............................................................................................... 2 8 ........................... 811315 ..................................... Rod (see Table) ................................................................................. 2 9 ........................... 810649 ..................................... Retaining Ring ................................................................................... 2 10 .......................... 810652 ..................................... Piston ................................................................................................ 2 11 .......................... 050012-065 .............................. Retaining Ring ................................................................................... 2 12 .......................... 811312 ..................................... Tube (see Table) ................................................................................ 2 13 .................... 810648 ..................................... Hose Burst Valve .................................................................................... 1
813822 ..................................... Seal Kit (included 1 - 4, 6, 7, 10) ............................................................. 2
Mast TL Lift Height
Positon 0
Position 8
Position 12
2400 mm
811310-101
811315-101
811312-101
2820 mm
811310-102
811315-102
811312-102
3220 mm
811310-002
811315-002
811312-002
3700 mm
811310-104
811315-104
811312-104
4200 mm
811310-105
811315-105
811312-105 Tab006gb
Mast TT Lift Height
Positon 0
Position 8
Position 12
3900 mm
811310-003
811315-003
811312-003
4250 mm
811310-003
811315-003
811312-003 Tab007gb
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-8.1-3130
83
FREE LIFT CYLINDER
1 1
2
3 3
4
2 5
5
4 6
6
7
~
7
8
8
12
12 9 10
11 13
9 10 11
13
MP-3130-802 MP-8.3-3130
84M1.0-0000-00084
MP-ST3000-GB 10/04 • Printed in Germany
FREE LIFT CYLINDER INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
0 ..................... 811319-*** ............................... Free Lift Cylinder Assembly (see Table) .................................................. 1 1 ........................... 811276 ..................................... Wiper Rod ......................................................................................... 1 2 ........................... 811280 ..................................... Rod Seal ........................................................................................... 1 3 ........................... 811321 ..................................... Cap .................................................................................................... 1 4 ........................... 054172 ..................................... Bleed Screw ...................................................................................... 1 054173 ..................................... Seal Ring ........................................................................................... 1 5 ........................... 812305 ..................................... Guide Ring ........................................................................................ 1 6 ........................... 811288 ..................................... Backring ............................................................................................ 1 7 ........................... 811284 ..................................... O-Ring ............................................................................................... 1 8 ........................... 811322-*** ................................ Rod .................................................................................................... 1 9 ........................... 811268 ..................................... Retaining Ring ................................................................................... 1 10 .......................... 811028 ..................................... Piston ................................................................................................ 1 11 .......................... 050012-009 .............................. Retaining Ring ................................................................................... 1 12 .......................... 811323-*** ................................ Tube ................................................................................................... 1 13 .......................... 811336 ..................................... Velocity Fuse ..................................................................................... 1
813820 ..................................... Seal Kit (included 1, 2, 4 - 7, 10) ............................................................. 1
Lift Height
Positon 0
Position 8
Position 12
3900 mm
811319-001
811322-001
811323-001
4250 mm
811319-001
811322-001
811323-001 Tab008gb
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-8.3-3130
85
Page intentionally left blank
Printed in Germany
86M1.0-0000-00086
SECTION 10
Printed in Germany
87
LABELS AND DECALS
2
1
1 6 7 8
3
4 5
6
9
10
12
11
6
13
MP-3130-1001 MP-10.9-3130
88M1.0-0000-00088
MP-ST3000-GB 10/04 • Printed in Germany
LABELS AND DECALS INDEX
PART NUMBER
PART NAME
NUMBER REQUIRED
1 ..................... 869006-*** ............................... Warning Hands Off ................................................................................. 2 2 ..................... 069374-001 .............................. Decal crown.com .................................................................................... 1 3 ........................................................................ Label Capacity Data ................................................................................ 1 4 ..................... 869054-*** ............................... Warning Moving Vehicle .......................................................................... 1 5 ..................... 869036-*** ............................... Warning No Riding .................................................................................. 1 6 ..................... 069372-027 .............................. Decal Momentum .................................................................................... 5 7 ..................... 869009-*** ............................... Warning Stand On ................................................................................... 2 8 ..................... 869010-*** ............................... Warning Stand Under .............................................................................. 2 9 ..................... 106158-020 .............................. Decal Crown Heavy ................................................................................ 2 10 .................... 869020-*** ............................... Danger Battery ....................................................................................... 1 11 .................... 869486-*** ............................... Info Point ................................................................................................. 1 12 .................... 869485-*** ............................... Warning Electrical Additions .................................................................... 1 13 ....................................................................... Plate Data ............................................................................................... 1
*** ................... xxxxxx-001 .............................. German xxxxxx-002 .............................. French xxxxxx-003 .............................. Spanish xxxxxx-004 .............................. Dutch xxxxxx-005 .............................. Italien xxxxxx-006 .............................. English xxxxxx-010 .............................. Portoguese
Always Specify Model & Serial Number To select part number, refer to truck data number. See Section ITD MP-ST3000-GB 10/04 • Printed in Germany
MP-10.9-3130
89
Page intentionally left blank
Printed in Germany
90M1.0-0000-00090