Crown Forklift ST3000 Series Parts Manual 812708

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

Page intentionally left blank

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