MP RT3010 GB - Rev2 - 04 02

Parts Manual
RT3010 Series
U1-Parts.p65 1 02.05.02, 11:32
TABLE OF CONTENT
Printed in Germany
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Printed in Germany
M1.0-0000-0002
M1.0-0000-0002
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TABLE OF CONTENT
Table of Content
MA – SAFETY PAGE SERIAL NR. CUT REV.

Safety Symbols used in the Manual ....................................... 7 ................................................................ Rev.1 01/01
ITD – INTRODUCTION PAGE SERIAL NR. CUT REV.

General .................................................................................. 11
Model-Number ........................................................................ 12
P-1.1 – LUBRICATION PAGE SERIAL NR. CUT REV.

Lubrication Type ..................................................................... 15
Grease Intervals .................................................................... 16
DIA – ELECTRICAL DIAGRAMS PAGE SERIAL NR. CUT REV.

Diagrams/Control Circuit ........................................................ 19
Diagrams/Control Circuit-Steering Motor ................................ 20
M/P – HYDRAULIC PAGE SERIAL NR. CUT REV.

Hydraulic Schematic .............................................................. 23
SECTION 1 – COVERS PAGE SERIAL NR. CUT REV.

Covers ................................................................................... 28
Caster Wheel ......................................................................... 30
SECTION 2 – HYDRAULIC PARTS PAGE SERIAL NR. CUT REV.

Tube/Hose Layout .................................................................. 34
Pumpen Motor and Pump ...................................................... 36
SECTION 3 – DRIVE UNIT PAGE SERIAL NR. CUT REV.

Gearbox ................................................................................. 40
Drive Motor ............................................................................ 42 .............................................................. Rev.1 04/02
SECTION 4 – ELEKTICAL PAGE SERIAL NR. CUT REV.

Elektrical Parts ...................................................................... 46,48,50
Directional Switch .................................................................. 52
Wiring Harness ....................................................................... 54,56
SECTION 6 – STEERING PAGE SERIAL NR. CUT REV.

Steering ................................................................................. 60,62
SECTION 7 – MAST/LIFT STRUCTURE PAGE SERIAL NR. CUT REV.

Lift Structure .......................................................................... 66 .............................................................. Rev.1 04/02
SECTION 8 – CYLINDER PAGE SERIAL NR. CUT REV.

Lift Cylinder ............................................................................ 70 .............................................................. Rev.1 04/02
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany M/P-IDX-2810

REV. 2 04/02
M1.0-0000-0003
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TABLE OF CONTENT
SECTION 10 – MISCELLANEOUS SERVICE INF. PAGE SERIAL NR. CUT REV.
Battery Trolley ........................................................................ 74
This Manual contains 76 Pages
M/P-IDX-2810 MP-RT3010_Rev.2-GB 04/02 • Printed in Germany
4 4M1.0-0000-0004
SAFETY
Printed in Germany
5
Printed in Germany
6 M1.0-0000-0006
SAFETY
Safety Symbols used in the General Maintenance and Repair

Manual Safety Notes
To help guide you through the manual and to highlight DANGER
particular danger areas, we have used graphic illustra-
tions: Read the safety notices in the truck Mainte-
nance and Operator's Manuals.
DANGER
● Failure to do so could result in severe or
This symbol indicates life-threatening risks fatal injuries to maintenance personnel and/
or other persons.
● Failure to comply with this notice may
result in severe or fatal injuries to yourself
or other people. Motorised vehicles can be dangerous if maintenance
and service are neglected. For this reason maintenance
and inspections must be carried out at regular short
intervals by trained personnel working to approved
WARNING
company guidelines.
This symbol indicates the risk of serious DANGER
injury and/or serious material damage.
Follow all national/local safety regulations
● Failure to comply with this notice may applicable for maintenance work, e.g. for
result in severe injuries to yourself or other work on higher levels.
people and/or serious material damage.
● Failure to do so could result in severe or
fatal injuries to maintenance personnel and/
or other persons.
CAUTION
Maintenance and Repair
This symbol indicates the risk of minor
injury and/or minor material damage. 1. Maintenance work must only be carried out in
accordance with the test and maintenance pro-
● Failure to comply with this notice may
gram contained in the present Maintenance
result in minor injuries to yourself or other
Manual and any applicable service notices.
people and/or minor material damage.
2. Only qualified and authorised personnel may carry
out work on the truck.
INFORMATION
3. Always keep fire extinguishers in good working
Contains additional information with condition. Do not approach fluid levels or leaks
supplementary notes and hints. with a naked flame.
4. To clean, use a non flammable, non combustible

OPTION cleaning solution which is groundwater-neutral.
Only carry out cleaning with an oil separator.
OPTION
These items relate to optional features not Protect the electrical system from dampness.
supplied with the standard version.
5. Keep the service area clean, dry and well-venti-
lated.
6. Do not allow oil to penetrate the ground or enter

the draining system. Used oil must be recycled.
Oil filters and desiccants must be treated as
special waste products. Relevant applicable
regulations must be followed.
7. Neutralise and thoroughly rinse any spilled battery

fluid immediately.
Printed in Germany M/P-MA-0000

REV. 1 4/00
M1.0-0000-0007
77
SAFETY
8. Keep the truck clean. This will facilitate the loca- Before Operating the Truck
tion of loose or faulty components.
● Check the safety devices.
9. Make sure that capacity and data plates, warnings
and labels are legible at all times. ● Get into the driver's seat.
10. Alterations or modifications by the owner or ● Check the operation of the lifting device, travel
operator are not permitted without the express direction switch, speed control, steering, warning
written authorisation from Crown. devices and brakes.
11. Only use original Crown spare parts to ensure the Warnings and Labels on the Truck
reliability, safety and suitability of the Crown truck.
During regular maintenance check that the warnings and
Before Leaving the Truck labels on the truck are complete and legible.
● Stop the truck. ● Clean any illegible labels.
● Lower the fork carriage fully. ● Replace any faulty or missing labels.
● Apply the parking brake. The order and meaning of the warnings and labels on
the truck are described in section 10.9 of the parts
● Turn off the travel switch and remove the key. manual.
● Block all wheels when parking on an uneven

surface.
Before Carrying out Work on the

Truck
● Raise the truck to free the drive wheel. Press the
emergency Stop button and disconnect the
battery.
● Prevent the truck from rolling away.
● Before carrying out work on the hoist frame, the

lift mast or on the fork carriage: Block these parts
according to maintenance instructions in order to
prevent them from dropping.
● Only carry out operational testing when there is

sufficient room to manoeuvre, to avoid the risk of
injury to yourself and others.
M/P-MA-0000 Printed in Germany

REV. 1 4/00
8 8M1.0-0000-0008
INTRODUCTION
Printed in Germany
9
Printed in Germany
M1.0-0000-00010
M1.0-0000-00010
10
INTRODUCTION
General Please refer to the Technical Specifications Sheet for the

utilisable loads, technical data and dimensions for this
The present manual is designed for Customer Service series. Brochures can be obtained from your CROWN
engineers who wish to familiarise themselves with the dealer or from the following address:
maintenance work required for the various truck compo-
nents.
CROWN Gabelstapler GmbH
It also contains troubleshooting sections which can be Moosacher Str. 52
used to identify and remedy truck faults. 80809 Munich
GERMANY
INFORMATION Tel.: +49 (0)89 / 93 002 -0
Fax: +49 (0)89 / 93 002 -175 oder 133
This book is not an operating manual. It is
designed solely for specialist personnel
who have been trained and authorised to
carry out the work described in the manual.
This manual therefore contains fewer and less detailed

warnings than the Operator's Manual, as the latter is aimed
at persons who have very little or no prior experience at
all.
Operating Instructions
This manual contains no operating instructions. An
operating instructions manual is supplied with the vehicle.
Additional copies can be ordered as required.
With the help of this manual you and your personnel will
be able to ensure the long service life, operational safety
and error free functioning of your CROWN vehicle.
Service Training
CROWN offers the appropriate vehicle related training for
service personnel. Details on this training can be obtained
from CROWN on request.
Ordering Spare Parts

Spare parts can be ordered by quoting:
● The truck specification number
● The truck model number
● The truck serial number
This information can be found on the truck's data plate.

Only if this information is provided can the order be
processed quickly, correctly and reliably.
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany M/P-ITD-2810
M1.0-0000-00011
11
11
INTRODUCTION
Model-Number
RT3010
Modeldescription
Low Level Order Picker, 2.000 kg capacity
M/P-ITD-2810 MP-RT3010_Rev.2-GB 04/02 • Printed in Germany
1212
M1.0-0000-00012
LUBRICATION AND ADJUSTMENT
Printed in Germany
13
Printed in Germany
14M1.0-0000-00014
LUBRICATION
Lubricant Type Product Description Manufacturer CROWN-Part-No. Type
Aralube HLP-2 Aral

LM-Grease Castrol
Regulus A2 Century
Grease (multi purpose) Beacon EP2 Esso 053002-001 B
EP2 Maxol
Mobiluxe E2 Mobil
Retinax LX Shell
Aralube SKL2 Aral

Low temperature grease 053002-005 BB
Unirex Lotemp EP Mobil
Kowal 40 Aral
Lubrication oil (chain) Essolube HDX Plus + 40 Esso 053002-007 G
Delvac 1240 Mobil
Low temperature
SHC 626 Mobil 053002-008 GG
lubrication oil
Vitam GF 32 Aral
Hyspin AWS-32 Castrol
Hydraulic oil Nuto H32 Esso 053001-003 D
DTE 24 Mobil
Tellus 32 Shell
Low temperature Univis J 13 Aral

053001-008 DD
hydraulic oil Aero HFA Mobil
Hyp 85W90 Aral

GX - D 85W90 Esso
Transmission oil 053002-004 A
Mobilube HD85/90 Mobil
Spirax MB 90 Shell
Low temperature
Mobilube SHC Mobil 053002-006 AA
transmission oil
Rubber and vinyl dressing H
Special grease MOS2 Lithium Dow Corning 063002-022 M
Universal lubrication oil SAE 40 C
L01-gb
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany P-1.1-2810
M1.0-0000-00015
15
15
LUBRICATION
Grease Points / Intervals
100 250 500 1000 2000

Item Component Type Vol.
hours hours hours hours hours
Check hydraulic oil level, replenish if

L-1 D A/R X
necessary
L-2 Replace hydraulic oil and filter D A/R Initially after 500 service hours X
L-3 All hinges C A/R X
L-4 Grease steering linkage B A/R X
L-5 Grease steering chain G A/R X
L-6 Drive unit live ring bearing B A/R X
L-7 Grease lifting mechanism B A/R X
L-8 Lift cylinder attachment B A/R X
L-9 Piston rod attachment B A/R X
L-10 Change gear oil A A/R Initially after 250 service hours X
L08-GB
P-1.2-2810 MP-RT3010_Rev.2-GB 04/02 • Printed in Germany
1616
M1.0-0000-00016
ELECTRICAL DIAGRAMS
Printed in Germany
17
Printed in Germany
M1.0-0000-00018
M1.0-0000-00018
18
BROWN/YELLOW BROWN/YELLOW
GREY/BLACK
RED/WHITE
YELLOW/RED
BLUE/WHITE
VIOLET
WHITE
BLACK BLUE
BROWN BLUE/BLACK
YELLOW/RED YELLOW/RED
BLUE
PINK
YELLOW/RED
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany

GREY/BLACK
GREY/BLACK
WHITE BLACK
VIOLET BROWN
GREEN BROWN
YELLOW BLUE
BLACK YELLOW/RED
RED BLACK
RED/WHITE
BLACK
BLUE/BLACK GREY
BLUE/WHITE
BLUE
BROWN WHITE
BLACK RED/WHITE
BROWN/BLACK VIOLET
BROWN
GREY
BLUE
BLUE
BROWN/YELLOW
YELLOW/RED
RED/GREEN
YELLOW/BLACK
RED RED RED/GREEN
RED/GREEN
BLAKE
M1.0-0000-00019
19
19
M/P-DIA-2810
M1797_gb
Control Circuit
DIAGRAMS
BROWN/YELLOW BROWN/YELLOW
GREY/BLACK
2020
RED/WHITE
M/P-DIA-2810
YELLOW/RED
BLUE/WHITE
VIOLET
WHITE
M1.0-0000-00020
BLACK BLUE
BROWN BLUE/BLACK
DIAGRAMS
YELLOW/RED YELLOW
BLUE
PINK
YELLOW/RED
GREY/BLACK
GREY/BLACK
Control Circuit/Steering Motor
WHITE BLACK
VIOLET BROWN
GREEN BROWN
YELLOW BLUE
BLACK YELLOW/RED
RED BLACK
RED/WHITE
BLACK
BLUE/BLACK GREY
BLUE/WHITE
BLUE
BROWN WHITE
BLACK RED/WHITE
BROWN/BLACK VIOLET
BROWN
GREY
BLUE
BLUE
BROWN/YELLOW
YELLOW/RED
RED/GREEN
YELLOW/BLACK
RED RED RED/GREEN
RED/GREEN
BLACK
GREY/BLACK
WHITE/BLACK
WHITE/GREEN
RED/BLACK
PINK
PINK/BLACK
YELLOW/BLACK
YELLOW
MP-RT3010_Rev.2-GB 04/02 • Printed in Germany

M1810_gb
YELLOW/RED
HYDRAULIC SCHEMATIC
Printed in Germany
21
Printed in Germany
M1.0-0000-00022
M1.0-0000-00022
22
HYDRAULIC SCHEMATIC
M1781
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany M/P-HYD-2810
M1.0-0000-00023
23
23
Printed in Germany
24
PARTS
Printed in Germany
25
Printed in Germany
26M1.0-0000-00026
SECTION 1
Printed in Germany
27
COVERS
M1764
MP-1.0-2810 MP-RT3010-Rev.2-GB 04/02 • Printed in Germany
28M1.0-0000-00028
COVERS
INDEX PART NUMBER PART NAME NUMBER REQUIRED
1 ..................... 809276-001 ............................ Screw ...................................................................................................... 8

2 ..................... 809210-004 ............................ Washer ................................................................................................... 8
3 ..................... 809277 .................................... Instrument Panel .................................................................................... 1
4 ..................... 809008-002 ............................ Handle .................................................................................................... 1
5 ..................... 809278-001 ............................ Support ................................................................................................... 1
6 ..................... 809279 .................................... Pad ......................................................................................................... 1
7 ..................... 809280-001 ............................ Nut .......................................................................................................... 1
8 ..................... 809278-002 ............................ Support ................................................................................................... 1
9 ..................... 809281 .................................... Cover ...................................................................................................... 1
10 ................... 809282-001 ............................ Fastener ................................................................................................. 2
11 ................... 809283 .................................... Hinge ...................................................................................................... 2
12 ................... 809232-004 ............................ Washer ................................................................................................... 4
13 ................... 809211-007 ............................ Screw ...................................................................................................... 4
14 ................... 809278-003 ............................ Support ................................................................................................... 1
15 ................... 809005-001 ............................ Washer ................................................................................................... 4
16 ................... 809006-002 ............................ Screw ...................................................................................................... 3
17 ................... 809284-001 ............................ Plug ........................................................................................................ 2
18 ................... 809285 .................................... Chassis .................................................................................................. 1
19 ................... 809276-002 ............................ Screw ...................................................................................................... 2
20 ................... 809006-008 ............................ Screw ...................................................................................................... 2
21 ................... 809004-002 ............................ Nut .......................................................................................................... 2
22 ................... 809286-001 ............................ Hose Clamp ........................................................................................... 1
23 ................... 809004-001 ............................ Nut .......................................................................................................... 1
24 ................... 809278-004 ............................ Support ................................................................................................... 1
25 ................... 809287 .................................... Fan .......................................................................................................... 2
26 ................... 809004-009 ............................ Nut .......................................................................................................... 8
27 ................... 809005-016 ............................ Washer ................................................................................................... 8
28 ................... 809142-003 ............................ Washer ................................................................................................... 8
29 ................... 809276-003 ............................ Screw ...................................................................................................... 8
30 ................... 809288 .................................... Finger Guard .......................................................................................... 2
31 ................... 809286-002 ............................ Hose Clamp ........................................................................................... 1
32 ................... 809006-012 ............................ Screw ...................................................................................................... 1
33 ................... 809278-005 ............................ Support ................................................................................................... 1
34 ................... 809005-007 ............................ Washer ................................................................................................... 1
35 ................... 809005-002 ............................ Washer ................................................................................................... 1
36 ................... 809276-004 ............................ Screw ...................................................................................................... 1
37 ................... 809296-002 ............................ Pin .......................................................................................................... 1
38 ................... 809276-005 ............................ Screw ...................................................................................................... 4
39 ................... 809289 .................................... Cover ...................................................................................................... 1
40 ................... 809290 .................................... Cover ...................................................................................................... 1
41 ................... 809006-005 ............................ Screw ...................................................................................................... 4
42 ................... 809291-001 ............................ Buffer ...................................................................................................... 2
43 ................... 809282-002 ............................ Fastener ................................................................................................. 2
44 ................... 809292 .................................... Lid ........................................................................................................... 1
45 ................... 809276-006 ............................ Screw ...................................................................................................... 3
46 ................... 809293 .................................... Floor Plate .............................................................................................. 1
47 ................... 809294 .................................... Floor Mat ................................................................................................ 1
48 ................... 809004-005 ............................ Nut .......................................................................................................... 1
49 ................... 809291-002 ............................ Buffer ...................................................................................................... 2
50 ................... 809295 .................................... Pedal ...................................................................................................... 1
51 ................... 809213-002 ............................ Spring ..................................................................................................... 1
52 ................... 809005-004 ............................ Washer ................................................................................................... 1
53 ................... 809276-007 ............................ Screw ...................................................................................................... 1
OPTIONAL
54 ................... 809278-006 ............................ Support ................................................................................................... 1
55 ................... 809006-004 ............................ Screw ...................................................................................................... 2
56 ................... 809280-002 ............................ Nut .......................................................................................................... 14
57 ................... 809005-017 ............................ Washer ................................................................................................... 14
58 ................... 809276-008 ............................ Screw ...................................................................................................... 14
59 ................... 809296-001 ............................ Pin .......................................................................................................... 7
60 ................... 809010-001 ............................ Roller ...................................................................................................... 7
Always Specify Model & Serial Number
MP-RT3010-Rev.2-GB 04/02 • Printed in Germany MP-1.0-2810
29
CASTER WHEEL
M1766
30M1.0-0000-00030
CASTER WHEEL
1 ..................... 809006-004 ............................ Screw ...................................................................................................... 2

2 ..................... 809301 .................................... Cover ...................................................................................................... 1
3 ..................... 809276-011 ............................ Screw ...................................................................................................... 6
4 ..................... 809005-018 ............................ Washer ................................................................................................... 6
5 ..................... 809302 .................................... Flange .................................................................................................... 1
6 ..................... 809177-002 ............................ Bearing Ball ........................................................................................... 1
7 ..................... 809303 .................................... Hub ......................................................................................................... 1
8 ..................... 809304 .................................... Grease Nipple ........................................................................................ 1
9 ..................... 809305-001 ............................ Bushing .................................................................................................. 2
10 ................... 809280-003 ............................ Nut .......................................................................................................... 1
11 ................... 809005-019 ............................ Washer ................................................................................................... 1
12 ................... 809296-004 ............................ Pin .......................................................................................................... 1
13 ................... 809013-008 ............................ Spacer .................................................................................................... 2
14 ................... 809004-010 ............................ Nut .......................................................................................................... 2
15 ................... 809013-009 ............................ Spacer .................................................................................................... 2
16 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 4
17 ................... 809013-010 ............................ Spacer .................................................................................................... 2
18 ................... 809306 .................................... Wheel ..................................................................................................... 2
19 ................... 809307 .................................... Axle ......................................................................................................... 1
20 ................... 809296-005 ............................ Pin .......................................................................................................... 1
21 ................... 809308 .................................... Caster Wheel Assy ................................................................................ 1
31
Printed in Germany
32M1.0-0000-00032
SECTION 2
Printed in Germany
33
TUBE/HOSE LAYOUT
M1770
34M1.0-0000-00034
TUBE/HOSE LAYOUT
1 ..................... 809335-001 ............................ Connector .............................................................................................. 2

2 ..................... 809087 .................................... Hose ....................................................................................................... 1
3 ..................... 809335-002 ............................ Connector .............................................................................................. 1
4 ..................... 809336-001 ............................ Hose ....................................................................................................... 1
5 ..................... 809497 .................................... Nut .......................................................................................................... 2
6 ..................... 809337 .................................... Solenoid ................................................................................................. 2
7 ..................... 809335-003 ............................ Connector .............................................................................................. 2
8 ..................... 809498-001 ............................ Lower Valve ............................................................................................ 1
9 ..................... 809499 .................................... Valve Block ............................................................................................. 1
10 ................... 809341 .................................... Flow Compensating Valve ..................................................................... 1
11 ................... 809498-002 ............................ Lift Valve ................................................................................................. 1
12 ................... 809501 .................................... Nut .......................................................................................................... 1
13 ................... 809502 .................................... Solenoid Valve ....................................................................................... 1
14 ................... 809276-018 ............................ Screw ...................................................................................................... 2
15 ................... 809029-004 ............................ Gasket .................................................................................................... 7
16 ................... 809211-009 ............................ Screw ...................................................................................................... 3
17 ................... 809336-002 ............................ Hose ....................................................................................................... 1
18 ................... 809108 .................................... Manometer Connector ........................................................................... 1
19 ................... 809343 .................................... Manifold Block ....................................................................................... 1
20 ................... 809005-001 ............................ Washer ................................................................................................... 2
21 ................... 809005-006 ............................ Washer ................................................................................................... 2
22 ................... 809006-019 ............................ Screw ...................................................................................................... 2
23 ................... 809344 .................................... Pressure Switch ..................................................................................... 1
24 ................... 809345 .................................... Tank ........................................................................................................ 1
25 ................... 809346 .................................... Rubber Plate .......................................................................................... 1
26 ................... 809347 .................................... Plug ........................................................................................................ 1
27 ................... 809348 .................................... Oil Filter .................................................................................................. 1
28 ................... 809335-004 ............................ Connector .............................................................................................. 1
29 ................... 809349-001 ............................ O-Ring .................................................................................................... 1
30 ................... 809350-001 ............................ Pipe ........................................................................................................ 1
31 ................... 809350-002 ............................ Pipe ........................................................................................................ 1
32 ................... 809351 .................................... Non Return Valve ................................................................................... 1
33 ................... 809352 .................................... Pressure Valve ....................................................................................... 1
34 ................... 809353 .................................... Pump Support ........................................................................................ 1
35 ................... 809349-002 ............................ O-Ring .................................................................................................... 2
36 ................... 809276-021 ............................ Screw ...................................................................................................... 4
37 ................... 809435 .................................... Support ................................................................................................... 1
38 ................... 809005-003 ............................ Washer ................................................................................................... 4
39 ................... 809276-019 ............................ Screw ...................................................................................................... 4
40 ................... 809354 .................................... Link ......................................................................................................... 2
41 ................... 809005-022 ............................ Washer ................................................................................................... 2
42 ................... 809280-011 ............................ Nut .......................................................................................................... 2
43 ................... 809355 .................................... Hydraulic Unit ........................................................................................ 1
35
PUMP MOTOR AND PUMP
M1771
36M1.0-0000-00036
PUMP MOTOR AND PUMP
1 ..................... 809356 .................................... Cover ...................................................................................................... 1

2 ..................... 809357-001 ............................ Circlip ..................................................................................................... 1
3 ..................... 809358-001 ............................ Spacer .................................................................................................... 1
4 ..................... 809359 .................................... Shield ..................................................................................................... 1
5 ..................... 809360 .................................... End Cover .............................................................................................. 1
6 ..................... 809361 .................................... Insulator ................................................................................................. 1
7 ..................... 809060-005 ............................ Spring ..................................................................................................... 4
8 ..................... 809362 .................................... Brush Kit ................................................................................................. 1
9 ..................... 809014-007 ............................ Bearing Ball ........................................................................................... 1
10 ................... 809357-002 ............................ Circlip ..................................................................................................... 1
11 ................... 809363 .................................... Armature ................................................................................................ 1
12 ................... 809358-002 ............................ Spacer .................................................................................................... 1
13 ................... 809014-008 ............................ Bearing Ball ........................................................................................... 1
14 ................... 809364 .................................... Motor Housing ....................................................................................... 1
15 ................... 809365 .................................... Drive End Plate ...................................................................................... 1
16 ................... 809367 .................................... Seal ........................................................................................................ 1
17 ................... 809358-003 ............................ Spacer .................................................................................................... 1
18 ................... 809026-008 ............................ O-Ring .................................................................................................... 1
19 ................... 809368 .................................... Tappet ..................................................................................................... 1
20 ................... 809369 .................................... Pump ...................................................................................................... 1
21 ................... 809005-024 ............................ Washer ................................................................................................... 2
22 ................... 809276-022 ............................ Screw ...................................................................................................... 2
23 ................... 809370 .................................... Pump Motor Assembly ........................................................................... 1
37
Printed in Germany
38M1.0-0000-00038
SECTION 3
Printed in Germany
39
GEAR BOX
M1774
40M1.0-0000-00040
GEAR BOX
1 ..................... 809211-010 ............................ Screw ...................................................................................................... 5

2 ..................... 809210-005 ............................ Washer ................................................................................................... 5
3 ..................... 809395 .................................... Rim ......................................................................................................... 1
4 ..................... 809396 .................................... Wheel (Vulkollan) ................................................................................. 1
809397 .................................... Wheel (Rubber) ..................................................................................... 1
5 ..................... 809398 .................................... Wheel Assembly (Vulkollan) ................................................................. 1
809399 .................................... Wheel Assembly (Rubber) .................................................................... 1
6 ..................... 809400-001 ............................ Seal ........................................................................................................ 1
7 ..................... 809069-007 ............................ Circlip ..................................................................................................... 1
8 ..................... 809175-004 ............................ Spacer .................................................................................................... 1
9 ..................... 809069-008 ............................ Circlip ..................................................................................................... 1
10 ................... 809014-009 ............................ Bearing Ball ........................................................................................... 2
11 ................... 809211-011 ............................ Screw ...................................................................................................... 1
12 ................... 809175-005 ............................ Spacer .................................................................................................... 4
13 ................... 809401-001 ............................ Gear ........................................................................................................ 1
14 ................... 809402 .................................... Housing .................................................................................................. 1
15 ................... 809400-002 ............................ Seal ........................................................................................................ 3
16 ................... 809403 .................................... Plug ........................................................................................................ 1
17 ................... 809005-005 ............................ Washer ................................................................................................... 3
18 ................... 809211-012 ............................ Screw ...................................................................................................... 3
19 ................... 809211-013 ............................ Screw ...................................................................................................... 9
20 ................... 809382 .................................... Washer ................................................................................................... 9
21 ................... 809211-015 ............................ Screw ...................................................................................................... 2
22 ................... 809349-003 ............................ O-Ring .................................................................................................... 1
23 ................... 809404 .................................... Grease Nipple ........................................................................................ 1
24 ................... 809405-001 ............................ Turntable ................................................................................................ 1
25 ................... 809211-014 ............................ Screw ...................................................................................................... 6
26 ................... 809405-002 ............................ Motor Flange .......................................................................................... 1
27 ................... 809401-002 ............................ Gear ........................................................................................................ 1
28 ................... 809349-004 ............................ O-Ring .................................................................................................... 1
29 ................... 809406 .................................... Gear ........................................................................................................ 1
30 ................... 809014-010 ............................ Bearing Ball ........................................................................................... 2
31 ................... 809176-006 ............................ Spacer .................................................................................................... 1
32 ................... 809401-003 ............................ Gear ........................................................................................................ 1
33 ................... 809280-005 ............................ Nut .......................................................................................................... 1
809407 .................................... Gear Box ................................................................................................ 1
41
DRIVE MOTOR
M1775

REV.1 04/02
42M1.0-0000-00042
DRIVE MOTOR
1 ..................... 809408 .................................... Support ................................................................................................... 1

2 ..................... 809286-002 ............................ Hose Clamp ........................................................................................... 1
3 ..................... 809005-001 ............................ Washer ................................................................................................... 1
4 ..................... 809006-012 ............................ Screw ...................................................................................................... 1
5 ..................... 809190-001 ............................ Spring ..................................................................................................... 7
6 ..................... 809409 .................................... ElectroMagnet ........................................................................................ 1
7 ..................... 805033 .................................... Screw Kit ................................................................................................ 1
8 ..................... 807763-004 ............................ Rotor Friction .......................................................................................... 1
9 ..................... 809410 .................................... Magnetic (Brake) .................................................................................... 1
10 ................... 805030 .................................... Hub ......................................................................................................... 1
11 ................... 809411-001 ............................ Woodruff Key .......................................................................................... 1
12 ................... 809415 .................................... Spring & Brush Holder ........................................................................... AR
13 ................... 809412 .................................... Brush Kit ................................................................................................. 1
14 ................... 809400-003 ............................ Gasket .................................................................................................... 1
15 ................... 809413 .................................... Flange .................................................................................................... 1
16 ................... 809411-002 ............................ Woodruff Key .......................................................................................... 1
17 ................... 809231-002 ............................ Screw ...................................................................................................... 8
18 ................... 809414-001 ............................ Drive Motor ............................................................................................. 1
19 ................... 809604 .................................... Shield ..................................................................................................... 1

REV.1 04/02
43
Printed in Germany
44M1.0-0000-00044
SECTION 4
Printed in Germany
45
ELECTRICAL PARTS
M1765
46M1.0-0000-00046
ELECTRICAL PARTS
1 ..................... 809006-014 ............................ Screw ...................................................................................................... 4

2 ..................... 809297 .................................... Guide ...................................................................................................... 2
3 ..................... 809005-008 ............................ Washer ................................................................................................... 4
4 ..................... 809005-004 ............................ Washer ................................................................................................... 4
5 ..................... 809004-005 ............................ Nut .......................................................................................................... 4
6 ..................... 809298 .................................... Push ....................................................................................................... 1
7 ..................... 809278-007 ............................ Support ................................................................................................... 1
8 ..................... 809208-001 ............................ Nut .......................................................................................................... 4
9 ..................... 809210-001 ............................ Washer ................................................................................................... 8
10 ................... 809209 .................................... Switch ..................................................................................................... 2
11 ................... 809276-009 ............................ Screw ...................................................................................................... 4
12 ................... 809142-003 ............................ Washer ................................................................................................... 6
13 ................... 809005-016 ............................ Washer ................................................................................................... 6
14 ................... 809006-025 ............................ Screw ...................................................................................................... 2
15 ................... 809004-009 ............................ Nut .......................................................................................................... 4
16 ................... 809299 .................................... Circlip ..................................................................................................... 1
17 ................... 809296-003 ............................ Pin .......................................................................................................... 1
18 ................... 809276-010 ............................ Screw ...................................................................................................... 1
19 ................... 809065-005 ............................ Circlip ..................................................................................................... 1
20 ................... 809014-004 ............................ Bearing Ball ........................................................................................... 1
21 ................... 809003-007 ............................ Buffer ...................................................................................................... 4
22 ................... 809300 .................................... Support ................................................................................................... 1
23 ................... 809211-004 ............................ Screw ...................................................................................................... 3
24 ................... 809136 .................................... Motor ...................................................................................................... 1
47
ELECTRICAL PARTS
M1777
48M1.0-0000-00048
ELECTRICAL PARTS
1 ..................... 809436 .................................... Controller ............................................................................................... 1

2 ..................... 809231-002 ............................ Screw ...................................................................................................... 4
3 ..................... 809232-001 ............................ Washer ................................................................................................... 4
4 ..................... 809246 .................................... Support ................................................................................................... 1
5 ..................... 809243 .................................... Contactor ................................................................................................ 2
6 ..................... 809233-002 ............................ Nut .......................................................................................................... 4
7 ..................... 809172-001 ............................ Washer ................................................................................................... 4
8 ..................... 809231-003 ............................ Screw ...................................................................................................... 4
9 ..................... 809231-004 ............................ Screw ...................................................................................................... 2
10 ................... 809005-005 ............................ Washer ................................................................................................... 2
11 ................... 809004-005 ............................ Nut .......................................................................................................... 4
12 ................... 809005-002 ............................ Washer ................................................................................................... 4
13 ................... 809005-007 ............................ Washer ................................................................................................... 2
14 ................... 809416 .................................... Screw ...................................................................................................... 2
15 ................... 809417 .................................... Plate ....................................................................................................... 1
16 ................... 809418 .................................... Fuse ........................................................................................................ 2
17 ................... 809233-001 ............................ Nut .......................................................................................................... 7
18 ................... 809005-004 ............................ Washer ................................................................................................... 7
19 ................... 809232-003 ............................ Washer ................................................................................................... 6
20 ................... 809232-002 ............................ Washer ................................................................................................... 8
21 ................... 809241 .................................... Buffer ...................................................................................................... 4
22 ................... 809231-005 ............................ Screw ...................................................................................................... 1
23 ................... 809232-004 ............................ Washer ................................................................................................... 1
24 ................... 809275 .................................... Support ................................................................................................... 1
25 ................... 809419 .................................... Fuse ........................................................................................................ 1
26 ................... 809247 .................................... Fuse Holder ........................................................................................... 1
OPTIONAL
27 ................... 809249 .................................... Programmer ........................................................................................... 1

28 ................... 809250-001 ............................ Connector .............................................................................................. 1
49
ELECTRICAL PARTS
M1778
50M1.0-0000-00050
ELECTRICAL PARTS
1 ..................... 809420 .................................... Nut .......................................................................................................... 2

2 ..................... 809421 .................................... Handle .................................................................................................... 1
3 ..................... 809422-001 ............................ Power Cable .......................................................................................... 1
4 ..................... 809423 .................................... Battery Connector .................................................................................. 2
5 ..................... 809006-017 ............................ Screw ...................................................................................................... 4
6 ..................... 809005-001 ............................ Washer ................................................................................................... 4
7 ..................... 809422-002 ............................ Power Cable .......................................................................................... 1
8 ..................... 809424 .................................... Grommet ................................................................................................ 2
9 ..................... 809425 .................................... Support ................................................................................................... 1
10 ................... 809426 .................................... Holder ..................................................................................................... 1
11 ................... 809005-008 ............................ Washer ................................................................................................... 2
12 ................... 809005-004 ............................ Washer ................................................................................................... 2
13 ................... 809006-004 ............................ Screw ...................................................................................................... 2
14 ................... 809428-001 ............................ Battery 285 Ah ....................................................................................... 1
809428-002 ............................ Battery 315 Ah ....................................................................................... 1
15 ................... 809429 .................................... Battery Tray ............................................................................................. 1
16 ................... 809224-001 ............................ Push ....................................................................................................... 1
17 ................... 809225 .................................... Contact ................................................................................................... 1
18 ................... 809430 .................................... Discharge Meter .................................................................................... 1
19 ................... 809226 .................................... Keyswitch ............................................................................................... 1
20 ................... 809224-002 ............................ Push Button ............................................................................................ 3
21 ................... 809224-003 ............................ Push Button ............................................................................................ 1
22 ................... 809231-007 ............................ Screw ...................................................................................................... 6
23 ................... 809005-016 ............................ Washer ................................................................................................... 6
24 ................... 809142-003 ............................ Washer ................................................................................................... 6
25 ................... 809264 .................................... Switch ..................................................................................................... 2
26 ................... 809259 .................................... Horn ........................................................................................................ 1
27 ................... 809256 .................................... Switch ..................................................................................................... 1
28 ................... 809394 .................................... Support ................................................................................................... 1
29 ................... 809431 .................................... Hose clamp ............................................................................................ 1
30 ................... 809432 .................................... Support ................................................................................................... 1
31 ................... 809276-004 ............................ Screw ...................................................................................................... 2
OPTIONAL
32 ................... 809006-027 ............................ Screw ...................................................................................................... 4

33 ................... 809172-001 ............................ Washer ................................................................................................... 4
34 ................... 809232-004 ............................ Washer ................................................................................................... 6
35 ................... 809258 .................................... Power Control Unit (Steering) ............................................................... 1
36 ................... 809242-004 ............................ Fuse ........................................................................................................ 1
37 ................... 809242-005 ............................ Fuse ........................................................................................................ 1
38 ................... 809231-005 ............................ Screw ...................................................................................................... 2
39 ................... 809243 .................................... Contactor ................................................................................................ 1
40 ................... 809257-002 ............................ Buzzer .................................................................................................... 1
51
DIRECTIONAL SWITCH
M1776
52M1.0-0000-00052
DIRECTIONAL SWITCH
1 ..................... 809203-001 ............................ Circlip ..................................................................................................... 1

2 ..................... 809204 .................................... Gear ........................................................................................................ 1
3 ..................... 809205 .................................... Cam ........................................................................................................ 1
4 ..................... 809206-001 ............................ Support ................................................................................................... 2
5 ..................... 809207 .................................... Potentiometer ......................................................................................... 1
6 ..................... 809208-001 ............................ Nut .......................................................................................................... 6
7 ..................... 809209 .................................... Switch ..................................................................................................... 2
8 ..................... 809210-001 ............................ Washer ................................................................................................... 4
9 ..................... 809211-001 ............................ Screw ...................................................................................................... 5
10 ................... 809211-002 ............................ Screw ...................................................................................................... 1
11 ................... 809212-001 ............................ Support ................................................................................................... 1
12 ................... 809213-001 ............................ Spring ..................................................................................................... 1
13 ................... 809214 .................................... Holder ..................................................................................................... 1
14 ................... 809210-002 ............................ Washer ................................................................................................... 1
15 ................... 809211-003 ............................ Screw ...................................................................................................... 1
16 ................... 809215-001 ............................ Shaft ....................................................................................................... 1
17 ................... 809216 .................................... Lever ...................................................................................................... 1
18 ................... 809211-004 ............................ Screw ...................................................................................................... 2
19 ................... 809203-002 ............................ Circlip ..................................................................................................... 2
20 ................... 809210-003 ............................ Washer ................................................................................................... 2
21 ................... 809217 .................................... Bushing .................................................................................................. 2
22 ................... 809142-003 ............................ Washer ................................................................................................... 1
23 ................... 809218 .................................... Pin .......................................................................................................... 1
24 ................... 809206-002 ............................ Support ................................................................................................... 1
25 ................... 809005-002 ............................ Washer ................................................................................................... 2
26 ................... 809006-015 ............................ Screw ...................................................................................................... 2
27 ................... 809219 .................................... Accelerator ............................................................................................. 1
53
WIRING HARNESS
Instrument Board
Armaturenbrett
Tablleau de bord
Accelerator
Fahrgeber
Accelerateur
M1779
54M1.0-0000-00054
WIRING HARNESS
1 ..................... 809433-001 ............................ Cable ...................................................................................................... 1

2 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
3 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
4 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
5 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
6 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
7 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
8 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
9 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
10 ................... 809433-002 ............................ Cable ...................................................................................................... 1
11 ................... 809433-002 ............................ Cable ...................................................................................................... 1
12 ................... 809433-002 ............................ Cable ...................................................................................................... 1
13 ................... 809433-003 ............................ Cable ...................................................................................................... 1
55
WIRING HARNESS
Instrument Board
Armaturenbrett
Tablleau de bord
Accelerator
Fahrgeber
Accelerateur
M1780
56M1.0-0000-00056
WIRING HARNESS
1 ..................... 809433-001 ............................ Cable ...................................................................................................... 1

2 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
3 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
4 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
5 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
6 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
7 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
8 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
9 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
10 ................... 809433-002 ............................ Cable ...................................................................................................... 1
11 ................... 809433-002 ............................ Cable ...................................................................................................... 1
12 ................... 809433-002 ............................ Cable ...................................................................................................... 1
13 ................... 809433-004 ............................ Cable ...................................................................................................... 1
14 ................... 809433-004 ............................ Cable ...................................................................................................... 1
15 ................... 809433-004 ............................ Cable ...................................................................................................... 1
16 ................... 809433-004 ............................ Cable ...................................................................................................... 1
17 ................... 809433-004 ............................ Cable ...................................................................................................... 1
18 ................... 809433-005 ............................ Cable ...................................................................................................... 1
57
Printed in Germany
58M1.0-0000-00058
SECTION 6
Printed in Germany
59
STEERING
M1772
60M1.0-0000-00060
STEERING
1 ..................... 809284-002 ............................ Plug ........................................................................................................ 1

2 ..................... 809371 .................................... Knob ....................................................................................................... 1
3 ..................... 809372 .................................... Steering Wheel ...................................................................................... 1
4 ..................... 809006-029 ............................ Screw ...................................................................................................... 1
5 ..................... 809005-005 ............................ Washer ................................................................................................... 1
6 ..................... 809005-009 ............................ Washer ................................................................................................... 1
7 ..................... 809371-001 ............................ Woodruff Key .......................................................................................... 1
8 ..................... 809374 .................................... Shaft ....................................................................................................... 1
9 ..................... 809373-002 ............................ Woodruff Key .......................................................................................... 1
10 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 4
11 ................... 809069-006 ............................ Circlip ..................................................................................................... 3
12 ................... 809376-001 ............................ Gear ........................................................................................................ 1
13 ................... 809377 .................................... Spacer .................................................................................................... 3
14 ................... 809069-001 ............................ Circlip ..................................................................................................... 2
15 ................... 809378 .................................... Chain ...................................................................................................... 1
16 ................... 809379-001 ............................ Link Extended ........................................................................................ 1
17 ................... 809376-002 ............................ Gear ........................................................................................................ 1
18 ................... 809305-007 ............................ Bushing .................................................................................................. 1
19 ................... 809296-015 ............................ Pin .......................................................................................................... 1
20 ................... 809376-003 ............................ Gear ........................................................................................................ 1
21 ................... 809380-001 ............................ Tappet ..................................................................................................... 1
22 ................... 809299 .................................... Circlip ..................................................................................................... 3
23 ................... 809381 .................................... Shaft ....................................................................................................... 1
24 ................... 809373-003 ............................ Woodruff Key .......................................................................................... 2
25 ................... 809014-008 ............................ Bearing Ball ........................................................................................... 2
26 ................... 809375-001 ............................ Circlip ..................................................................................................... 1
27 ................... 809276-011 ............................ Screw ...................................................................................................... 1
28 ................... 809004-002 ............................ Nut .......................................................................................................... 2
29 ................... 809278-009 ............................ Support ................................................................................................... 1
30 ................... 809382 .................................... Washer ................................................................................................... 3
31 ................... 809142-001 ............................ Washer ................................................................................................... 2
32 ................... 809276-019 ............................ Screw ...................................................................................................... 2
33 ................... 809269-016 ............................ Pin .......................................................................................................... 2
34 ................... 809383 .................................... Cardan shaft .......................................................................................... 1
35 ................... 809375-002 ............................ Circlip ..................................................................................................... 1
36 ................... 809005-008 ............................ Washer ................................................................................................... 4
37 ................... 809005-004 ............................ Washer ................................................................................................... 4
38 ................... 809006-007 ............................ Screw ...................................................................................................... 4
39 ................... 809278-010 ............................ Support ................................................................................................... 1
40 ................... 809384 .................................... Shaft ....................................................................................................... 1
41 ................... 809144 .................................... Link Extended ........................................................................................ 2
42 ................... 809379-002 ............................ Link Extended ........................................................................................ 1
43 ................... 809376-004 ............................ Gear ........................................................................................................ 1
44 ................... 809145 .................................... Chain ...................................................................................................... 1
45 ................... 809385 .................................... Chain Adjuster ....................................................................................... 1
61
STEERING
M1773
62M1.0-0000-00062
STEERING
1 ..................... 809284-002 ............................ Plug ........................................................................................................ 1

2 ..................... 809371 .................................... Knob ....................................................................................................... 1
3 ..................... 809372 .................................... Steering Wheel ...................................................................................... 1
4 ..................... 809006-029 ............................ Screw ...................................................................................................... 3
5 ..................... 809005-005 ............................ Washer ................................................................................................... 3
6 ..................... 809005-009 ............................ Washer ................................................................................................... 1
7 ..................... 809371-001 ............................ Woodruff Key .......................................................................................... 1
8 ..................... 809386 .................................... Shaft ....................................................................................................... 1
9 ..................... 809006-026 ............................ Screw ...................................................................................................... 1
10 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 1
11 ................... 809305-008 ............................ Bushing .................................................................................................. 1
12 ................... 809276-024 ............................ Screw ...................................................................................................... 1
13 ................... 809014-014 ............................ Bearing Ball ........................................................................................... 1
14 ................... 809299 .................................... Circlip ..................................................................................................... 1
15 ................... 809142-003 ............................ Washer ................................................................................................... 14
16 ................... 809003-007 ............................ Buffer ...................................................................................................... 4
17 ................... 809005-016 ............................ Washer ................................................................................................... 13
18 ................... 809004-009 ............................ Nut .......................................................................................................... 4
19 ................... 809231-001 ............................ Screw ...................................................................................................... 3
20 ................... 809135-002 ............................ Flange .................................................................................................... 1
21 ................... 809136 .................................... Motor ...................................................................................................... 1
22 ................... 809005-025 ............................ Washer ................................................................................................... 2
23 ................... 809276-025 ............................ Screw ...................................................................................................... 2
24 ................... 809387 .................................... Shield ..................................................................................................... 1
25 ................... 809060-006 ............................ Spring ..................................................................................................... 2
26 ................... 809388 .................................... Brush Kit ................................................................................................. 1
27 ................... 809373-004 ............................ Woodruff Key .......................................................................................... 1
28 ................... 809389 .................................... Motor ...................................................................................................... 1
29 ................... 809390 .................................... Gear Box ................................................................................................ 1
30 ................... 809278-011 ............................ Support ................................................................................................... 1
31 ................... 809005-004 ............................ Washer ................................................................................................... 4
32 ................... 809006-014 ............................ Screw ...................................................................................................... 4
33 ................... 809142-001 ............................ Washer ................................................................................................... 2
34 ................... 809382 .................................... Washer ................................................................................................... 2
35 ................... 809276-019 ............................ Screw ...................................................................................................... 2
36 ................... 809391 .................................... Gear ........................................................................................................ 1
37 ................... 809005-026 ............................ Washer ................................................................................................... 1
38 ................... 809005-027 ............................ Washer ................................................................................................... 1
39 ................... 809005-002 ............................ Washer ................................................................................................... 1
40 ................... 809006-012 ............................ Screw ...................................................................................................... 1
41 ................... 809145 .................................... Chain ...................................................................................................... 1
42 ................... 809144 .................................... Link Extended ........................................................................................ 2
43 ................... 809385 .................................... Chain Adjuster ....................................................................................... 1
44 ................... 809231-007 ............................ Screw ...................................................................................................... 6
45 ................... 809264 .................................... Switch ..................................................................................................... 2
46 ................... 809392 .................................... Support ................................................................................................... 1
47 ................... 809006-027 ............................ Screw ...................................................................................................... 2
48 ................... 809172-001 ............................ Washer ................................................................................................... 2
49 ................... 809393-001 ............................ Cam ........................................................................................................ 1
50 ................... 809393-002 ............................ Cam ........................................................................................................ 1
51 ................... 809231-005 ............................ Screw ...................................................................................................... 4
52 ................... 809256 .................................... Switch ..................................................................................................... 1
53 ................... 809394 .................................... Support ................................................................................................... 1
63
Printed in Germany
64M1.0-0000-00064
SECTION 7
Printed in Germany
65
LIFT STRUCTURE
M1769
66M1.0-0000-00066
LIFT STRUCTURE
1 ..................... 809276-014 ............................ Screw ...................................................................................................... 6

2 ..................... 809319 .................................... Cover ...................................................................................................... 1
3 ..................... 809006-033 ............................ Screw ...................................................................................................... 1
4 ..................... 809005-003 ............................ Washer ................................................................................................... 1
5 ..................... 809002-003 ............................ Gas Strut ................................................................................................ 1
6 ..................... 809434 .................................... Forks ....................................................................................................... 1
7 ..................... 809320 .................................... Cover ...................................................................................................... 1
8 ..................... 809276-015 ............................ Screw ...................................................................................................... 4
9 ..................... 809069-002 ............................ Circlip ..................................................................................................... 12
10 ................... 809296-008 ............................ Pin .......................................................................................................... 6
11 ................... 809321 .................................... Roller ...................................................................................................... 6
12 ................... 809069-006 ............................ Circlip ..................................................................................................... 6
13 ................... 809013-004 ............................ Spacer .................................................................................................... 4
14 ................... 809078 .................................... Guide ...................................................................................................... 4
15 ................... 809013-014 ............................ Spacer .................................................................................................... 8
16 ................... 809322 .................................... Lever ...................................................................................................... 4
17 ................... 809305-009 ............................ Bushing .................................................................................................. 6
18 ................... 809280-007 ............................ Nut .......................................................................................................... 2
19 ................... 809605 .................................... Washer ................................................................................................... 2
20 ................... 809305-002 ............................ Bushing .................................................................................................. 4
21 ................... 809323 .................................... Link (RH) ................................................................................................ 1
22 ................... 809323 .................................... Link (LH) ................................................................................................ 1
23 ................... 809305-008 ............................ Bushing .................................................................................................. 2
24 ................... 809296-009 ............................ Pin .......................................................................................................... 2
25 ................... 809324 .................................... Plate ....................................................................................................... 2
26 ................... 809006-015 ............................ Screw ...................................................................................................... 4
27 ................... 809276-013 ............................ Screw ...................................................................................................... 2
28 ................... 809004-002 ............................ Nut .......................................................................................................... 2
29 ................... 809269-017 ............................ Split pin .................................................................................................. 2
30 ................... 809269-018 ............................ Pin .......................................................................................................... 2
31 ................... 809325 .................................... Link ......................................................................................................... 1
32 ................... 809296-010 ............................ Pin .......................................................................................................... 2
33 ................... 809326 .................................... Link (RH) ................................................................................................ 1
34 ................... 809326 .................................... Link (LH) ................................................................................................ 1
35 ................... 809296-011 ............................ Pin .......................................................................................................... 2
36 ................... 809327 .................................... Plate ....................................................................................................... 2
37 ................... 809013-015 ............................ Spacer .................................................................................................... 4
38 ................... 809065-002 ............................ Ball joint ................................................................................................. 2
39 ................... 809280-008 ............................ Nut .......................................................................................................... 2
40 ................... 809328 .................................... Tension Bar ............................................................................................ 2
41 ................... 809054 .................................... Bushing .................................................................................................. 2
42 ................... 809305-004 ............................ Bushing .................................................................................................. 2
43 ................... 809296-012 ............................ Pin .......................................................................................................... 2
44 ................... 809296-013 ............................ Pin .......................................................................................................... 2
45 ................... 809304 .................................... Grease Nipple ........................................................................................ 2
46 ................... 809329 .................................... Riser ....................................................................................................... 2
47 ................... 809296-014 ............................ Pin .......................................................................................................... 2
48 ................... 809276-002 ............................ Screw ...................................................................................................... 2
49 ................... 809305-005 ............................ Bushing .................................................................................................. 4
50 ................... 809305-006 ............................ Bushing .................................................................................................. 4
51 ................... 809330 .................................... Plate Side ............................................................................................... 4
52 ................... 809276-016 ............................ Screw ...................................................................................................... 4
53 ................... 809276-017 ............................ Screw ...................................................................................................... 4
54 ................... 809331 .................................... Axle ......................................................................................................... 4
55 ................... 809332 .................................... Ring ........................................................................................................ 8
56 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 8
57 ................... 809333 .................................... Load Roller (Vulkollan) .......................................................................... 4
58 ................... 809334 .................................... Riser Assembly ...................................................................................... 2

REV. 1 04/02
67
Printed in Germany
68M1.0-0000-00068
SECTION 8
Printed in Germany
69
LIFT CYLINDER
M1768

REV.1 04/02
70M1.0-0000-00070
LIFT CYLINDER
1 ..................... 809314 .................................... Cylinder Tube ......................................................................................... 1

2 ..................... 809280-005 ............................ Nut .......................................................................................................... 1
3 ..................... 809315 .................................... Ring Retaining ....................................................................................... 1
4 ..................... 809028 .................................... Piston ...................................................................................................... 1
5 ..................... 809026-002 ............................ Ring ........................................................................................................ 1
6 ..................... 809029-001 ............................ Gasket .................................................................................................... 1
7 ..................... 809316 .................................... Piston Rod ............................................................................................. 1
8 ..................... 809026-001 ............................ O-Ring .................................................................................................... 1
9 ..................... 809317 .................................... Cylinder Nut ........................................................................................... 1
10 ................... 809024-001 ............................ Seal ........................................................................................................ 1
11 ................... 809023-001 ............................ Wiper ...................................................................................................... 1
12 ................... 809280-006 ............................ Nut .......................................................................................................... 1
13 ................... 809023-001 ............................ Rod End ................................................................................................. 1
14 ................... 809318 .................................... Cylinder Assembly ................................................................................. 1
(without 13)
809033-001 ............................ Seal Kit ................................................................................................... 1

(incl. 5,6,8,10,11)

REV. 1 04/02
71
Printed in Germany
72M1.0-0000-00072
SECTION 10
Printed in Germany
73
BATTERY TROLLEY
M1767
74M1.0-0000-00074
BATTERY TROLLEY
1 ..................... 809309 .................................... Chassis .................................................................................................. 1

2 ..................... 809310 .................................... Wheel ..................................................................................................... 3
3 ..................... 809311 .................................... Tiller ........................................................................................................ 1
4 ..................... 809060-004 ............................ Spring ..................................................................................................... 1
5 ..................... 809296-006 ............................ Pin .......................................................................................................... 1
6 ..................... 809069-001 ............................ Circlip ..................................................................................................... 2
7 ..................... 809280-004 ............................ Nut .......................................................................................................... 1
8 ..................... 809013-011 ............................ Spacer .................................................................................................... 2
9 ..................... 809014-006 ............................ Bearing Ball ........................................................................................... 6
10 ................... 809312 .................................... Wheel ..................................................................................................... 3
11 ................... 809013-012 ............................ Spacer .................................................................................................... 1
12 ................... 809276-012 ............................ Screw ...................................................................................................... 1
13 ................... 809004-002 ............................ Nut .......................................................................................................... 4
14 ................... 809142-001 ............................ Washer ................................................................................................... 4
15 ................... 809278-008 ............................ Support ................................................................................................... 1
16 ................... 809276-013 ............................ Screw ...................................................................................................... 4
17 ................... 809013-013 ............................ Spacer .................................................................................................... 4
18 ................... 809296-007 ............................ Pin .......................................................................................................... 2
809313 .................................... Battery Trolley Assembly ........................................................................ 1
75
Printed in Germany
76M1.0-0000-00076
CROWN Gabelstapler GmbH & Co. KG
- European Headquarter -
Moosacher Str. 52
80809 Munich
Germany
Telephone +49 (0)89 93 00 2 - 0
Telefax +49 (0)89 93 00 2 -175 or -133
Printed in Germany • Revision Level C

Order Number: 812698-006

MP RT3010 GB - Rev2 - 04 02

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Parts Manual

MA – SAFETY PAGE SERIAL NR. CUT REV.

ITD – INTRODUCTION PAGE SERIAL NR. CUT REV.

P-1.1 – LUBRICATION PAGE SERIAL NR. CUT REV.

DIA – ELECTRICAL DIAGRAMS PAGE SERIAL NR. CUT REV.

M/P – HYDRAULIC PAGE SERIAL NR. CUT REV.

SECTION 1 – COVERS PAGE SERIAL NR. CUT REV.

SECTION 2 – HYDRAULIC PARTS PAGE SERIAL NR. CUT REV.

SECTION 3 – DRIVE UNIT PAGE SERIAL NR. CUT REV.

SECTION 4 – ELEKTICAL PAGE SERIAL NR. CUT REV.

SECTION 6 – STEERING PAGE SERIAL NR. CUT REV.

SECTION 7 – MAST/LIFT STRUCTURE PAGE SERIAL NR. CUT REV.

SECTION 8 – CYLINDER PAGE SERIAL NR. CUT REV.

MP-RT3010-Rev.2-GB 04/02 • Printed in Germany M/P-IDX-2810

This Manual contains 76 Pages

M/P-IDX-2810 MP-RT3010_Rev.2-GB 04/02 • Printed in Germany

Safety Symbols used in the General Maintenance and Repair

4. To clean, use a non flammable, non combustible

6. Do not allow oil to penetrate the ground or enter

7. Neutralise and thoroughly rinse any spilled battery

Printed in Germany M/P-MA-0000

● Stop the truck. ● Clean any illegible labels.

● Block all wheels when parking on an uneven

Before Carrying out Work on the

● Prevent the truck from rolling away.

● Before carrying out work on the hoist frame, the

● Only carry out operational testing when there is

M/P-MA-0000 Printed in Germany

General Please refer to the Technical Specifications Sheet for the

This manual therefore contains fewer and less detailed

Ordering Spare Parts

● The truck specification number

● The truck model number

● The truck serial number

This information can be found on the truck's data plate.

MP-RT3010-Rev.2-GB 04/02 • Printed in Germany M/P-ITD-2810

Low Level Order Picker, 2.000 kg capacity

M/P-ITD-2810 MP-RT3010_Rev.2-GB 04/02 • Printed in Germany

Lubricant Type Product Description Manufacturer CROWN-Part-No. Type

Aralube HLP-2 Aral

Aralube SKL2 Aral

Low temperature Univis J 13 Aral

Hyp 85W90 Aral

Rubber and vinyl dressing H

Special grease MOS2 Lithium Dow Corning 063002-022 M

Universal lubrication oil SAE 40 C

MP-RT3010-Rev.2-GB 04/02 • Printed in Germany P-1.1-2810

Grease Points / Intervals

100 250 500 1000 2000

Check hydraulic oil level, replenish if

L-3 All hinges C A/R X

L-4 Grease steering linkage B A/R X

L-5 Grease steering chain G A/R X

L-6 Drive unit live ring bearing B A/R X

L-7 Grease lifting mechanism B A/R X

L-8 Lift cylinder attachment B A/R X

L-9 Piston rod attachment B A/R X

P-1.2-2810 MP-RT3010_Rev.2-GB 04/02 • Printed in Germany

MP-RT3010-Rev.2-GB 04/02 • Printed in Germany

MP-RT3010_Rev.2-GB 04/02 • Printed in Germany

MP-RT3010-Rev.2-GB 04/02 • Printed in Germany M/P-HYD-2810

MP-1.0-2810 MP-RT3010-Rev.2-GB 04/02 • Printed in Germany

1 ..................... 809276-001 ............................ Screw ...................................................................................................... 8