Parts Manual

RT3020 Series
U1-Parts.p65 1 02.05.02, 13:55
 TABLE OF CONTENT

Printed in Germany

1
 Page intentionally left blank

Printed in Germany

M1.0-0000-0002
M1.0-0000-0002
2
 TABLE OF CONTENT

Table of Content

MA – SAFETY PAGE SERIAL NR. CUT REV.

Safety Symbols used in the Manual ....................................... 7 ................................................................ Rev.1 01/01

ITD – INTRODUCTION PAGE SERIAL NR. CUT REV.

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
Wiring Harness ....................................................................... 52,54

SECTION 6 – STEERING PAGE SERIAL NR. CUT REV.

Steering ................................................................................. 58,60 ......................................................... Rev.1 04/02

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

Lift Structure .......................................................................... 64 .............................................................. Rev.1 04/02

SECTION 8 – CYLINDER PAGE SERIAL NR. CUT REV.

Lift Cylinder ............................................................................ 68 .............................................................. Rev.1 04/02

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany M/P-IDX-2910

REV. 2 04/02
M1.0-0000-0003
33
TABLE OF CONTENT
SECTION 10 – MISCELLANEOUS SERVICE INF. PAGE SERIAL NR. CUT REV.
Battery Trolley ........................................................................ 72

This Manual contains 74 Pages

M/P-IDX-2910 MP-RT3020_Rev.2-GB 04/02 • Printed in Germany

4 4M1.0-0000-0004
 SAFETY

Printed in Germany

5
 Page intentionally left blank

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
 Page intentionally left blank

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-RT3020-Rev.2-GB 04/02 • Printed in Germany M/P-ITD-2910

M1.0-0000-00011
11
11
INTRODUCTION

Model-Number

RT3020

Modeldescription

Rider Pallet Truck with 2.200 kg capacity

M/P-ITD-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

1212
M1.0-0000-00012
 LUBRICATION AND ADJUSTMENT

Printed in Germany

13
 Page intentionally left blank

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-RT3020-Rev.2-GB 04/02 • Printed in Germany P-1.1-2910

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

L-11 Seat rails B A/R X

L08-GB

P-1.2-2910 MP-RT3020_Rev.2-GB 04/02 • Printed in Germany

1616
M1.0-0000-00016
 ELECTRICAL DIAGRAMS

Printed in Germany

17
 Page intentionally left blank

Printed in Germany

M1.0-0000-00018
M1.0-0000-00018
18
 GREY/BLACK

RED/WHITE

WHITE

YELLOW

VIOLET

BROWN/YELLOW
BLUE/WHITE
YELLOW
BLACK BLUE
BROWN BLUE/BLACK
YELLOW/RED
PINK

BROWN/BLACK
BROWN/BLACK
BROWN
BLUE

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

YELLOW/RED

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
BLACK

M1.0-0000-00019
19
19
M/P-DIA-2910
Control Circuit
DIAGRAMS

M1818_gb
 GREY/BLACK
BLACK

2020
RED/WHITE

YELLOW

VIOLET
WHITE

M/P-DIA-2910
BROWN/YELLOW
YELLOW
BROWN/WHITE

M1.0-0000-00020
BLACK BLUE
BROWN BLUE/BLACK
YELLOW/RED
DIAGRAMS

PINK
YELLOW/RED

BLUE

BROWN/BLACK
BROWN/BLACK
BROWN
GREY/BLACK
GREY/BLACK

WHITE BLACK
Control Circuit/Steering Motor

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/
BLACK
PINK

YELLOW/BLACK

MP-RT3020_Rev.2-GB 04/02 • Printed in Germany

M1856_gb
YELLOW YELLOW/RED
 HYDRAULIC SCHEMATIC

Printed in Germany

21
 Page intentionally left blank

Printed in Germany

M1.0-0000-00022
M1.0-0000-00022
22
 HYDRAULIC SCHEMATIC

M1781

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany M/P-HYD-2910

M1.0-0000-00023
23
23
 Page intentionally left blank

PrintedM/P-HYD-2910
in Germany

24
 PARTS

Printed in Germany

25
 Page intentionally left blank

Printed in Germany

26M1.0-0000-00026
 SECTION 1

Printed in Germany

27
COVERS

M1782

MP-1.0-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

28M1.0-0000-00028
 COVERS
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809437 .................................... Fastener ................................................................................................. 1

2 ..................... 809004-001 ............................ Nut .......................................................................................................... 3
3 ..................... 809438-001 ............................ Support ................................................................................................... 1
4 ..................... 809439 .................................... Pad ......................................................................................................... 1
5 ..................... 809276-004 ............................ Screw ...................................................................................................... 6
6 ..................... 809005-007 ............................ Washer ................................................................................................... 12
7 ..................... 809438-003 ............................ Support ................................................................................................... 1
8 ..................... 809440-001 ............................ Cover ...................................................................................................... 1
9 ..................... 809005-002 ............................ Washer ................................................................................................... 12
10 ................... 809004-005 ............................ Nut .......................................................................................................... 4
11 ................... 809006-014 ............................ Screw ...................................................................................................... 2
12 ................... 809005-004 ............................ Washer ................................................................................................... 2
13 ................... 809005-008 ............................ Washer ................................................................................................... 2
14 ................... 809426 .................................... Holder ..................................................................................................... 1
15 ................... 809441 .................................... Split pin .................................................................................................. 2
16 ................... 809442 .................................... Gas Strut ................................................................................................ 1
17 ................... 809283-001 ............................ Hinge (RH) ............................................................................................. 1
809283-002 ............................ Hinge (LH) ............................................................................................. 1
18 ................... 809232-004 ............................ Washer ................................................................................................... 4
19 ................... 809211-007 ............................ Screw ...................................................................................................... 4
20 ................... 809443 .................................... Chassis .................................................................................................. 1
21 ................... 809444-001 ............................ Shield ..................................................................................................... 1
22 ................... 809276-005 ............................ Screw ...................................................................................................... 4
23 ................... 809006-002 ............................ Screw ...................................................................................................... 2
24 ................... 809005-001 ............................ Washer ................................................................................................... 6
25 ................... 809445 .................................... Hose Clamp ........................................................................................... 1
26 ................... 809004-002 ............................ Nut .......................................................................................................... 2
27 ................... 809006-033 ............................ Screw ...................................................................................................... 2
28 ................... 809286-001 ............................ Hose Clamp ........................................................................................... 1
29 ................... 809490 .................................... Floor Mat ................................................................................................ 1
30 ................... 809446 .................................... Floor Plate .............................................................................................. 1
31 ................... 809444-002 ............................ Shield ..................................................................................................... 1
32 ................... 809276-006 ............................ Screw ...................................................................................................... 4
33 ................... 809447 .................................... Buffer ...................................................................................................... 1
34 ................... 809006-005 ............................ Screw ...................................................................................................... 4
35 ................... 809440-002 ............................ Cover ...................................................................................................... 1
36 ................... 809006-015 ............................ Screw ...................................................................................................... 6
37 ................... 809440-003 ............................ Cover ...................................................................................................... 1
38 ................... 809448-001 ............................ Instrument Panel .................................................................................... 1
39 ................... 809448-002 ............................ Instrument Panel .................................................................................... 1
40 ................... 809449 .................................... Lid ........................................................................................................... 1
41 ................... 809282-002 ............................ Fastener ................................................................................................. 2
42 ................... 809004-004 ............................ Nut .......................................................................................................... 4
43 ................... 809006-007 ............................ Screw ...................................................................................................... 4
44 ................... 809450 .................................... Seat ........................................................................................................ 1
45 ................... 809451 .................................... Switch ..................................................................................................... 1

OPTIONAL

46 ................... 809438-002 ............................ Support ................................................................................................... 1

47 ................... 809006-004 ............................ Screw ...................................................................................................... 2
48 ................... 809280-002 ............................ Nut .......................................................................................................... 12
49 ................... 809005-017 ............................ Washer ................................................................................................... 12
50 ................... 809276-008 ............................ Screw ...................................................................................................... 12
51 ................... 809296-001 ............................ Pin .......................................................................................................... 6
52 ................... 809010-001 ............................ Roller ...................................................................................................... 6
53 ................... 809451-001 ............................ Spacer .................................................................................................... 1
54 ................... 809005-001 ............................ Washer ................................................................................................... 1
55 ................... 809005-002 ............................ Washer ................................................................................................... 1
56 ................... 809276-004 ............................ Screw ...................................................................................................... 1
57 ................... 809451-002 ............................ Spacer .................................................................................................... 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-1.0-2910

29
CASTER WHEEL

M1766

MP-1.5-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

30M1.0-0000-00030
 CASTER WHEEL
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809006-004 ............................ Screw ...................................................................................................... 2

2 ..................... 809301 .................................... Cover ...................................................................................................... 1
3 ..................... 809276-011 ............................ Screw ...................................................................................................... 6
4 ..................... 809005-018 ............................ Washer ................................................................................................... 6
5 ..................... 809302 .................................... Flange .................................................................................................... 1
6 ..................... 809177-002 ............................ Bearing Ball ........................................................................................... 1
7 ..................... 809303 .................................... Hub ......................................................................................................... 1
8 ..................... 809304 .................................... Grease Nipple ........................................................................................ 1
9 ..................... 809305-001 ............................ Bushing .................................................................................................. 2
10 ................... 809280-003 ............................ Nut .......................................................................................................... 1
11 ................... 809005-019 ............................ Washer ................................................................................................... 1
12 ................... 809296-004 ............................ Pin .......................................................................................................... 1
13 ................... 809013-008 ............................ Spacer .................................................................................................... 2
14 ................... 809004-010 ............................ Nut .......................................................................................................... 2
15 ................... 809013-009 ............................ Spacer .................................................................................................... 2
16 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 4
17 ................... 809013-010 ............................ Spacer .................................................................................................... 2
18 ................... 809306 .................................... Wheel ..................................................................................................... 2
19 ................... 809307 .................................... Axle ......................................................................................................... 1
20 ................... 809296-005 ............................ Pin .......................................................................................................... 1
21 ................... 809308 .................................... Caster Wheel Assembly ........................................................................ 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-1.5-2910

31
 Page intentionally left blank

Printed in Germany

32M1.0-0000-00032
 SECTION 2

Printed in Germany

33
TUBE/HOSE LAYOUT

M1784

MP-2.1-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

34M1.0-0000-00034
 TUBE/HOSE LAYOUT
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809335-001 ............................ Connector .............................................................................................. 2

2 ..................... 809087 .................................... Hose ....................................................................................................... 1
3 ..................... 809335-002 ............................ Connector .............................................................................................. 1
4 ..................... 809455-001 ............................ 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 ................... 809455-002 ............................ 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 ................... 809456 .................................... Buffer ...................................................................................................... 2
38 ................... 809142-001 ............................ Washer ................................................................................................... 2
39 ................... 809004-011 ............................ Screw ...................................................................................................... 2
40 ................... 809354 .................................... Link ......................................................................................................... 2
41 ................... 809005-022 ............................ Washer ................................................................................................... 2
42 ................... 809280-011 ............................ Nut .......................................................................................................... 2
43 ................... 809355 .................................... Hydraulic Unit ........................................................................................ 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-2.1-2910

35
PUMP MOTOR AND PUMP

M1771

MP-2.13-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

36M1.0-0000-00036
 PUMP MOTOR AND PUMP
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809356 .................................... Cover ...................................................................................................... 1

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

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-2.13-2910

37
 Page intentionally left blank

Printed in Germany

38M1.0-0000-00038
 SECTION 3

Printed in Germany

39
GEAR BOX

M1774

MP-3.1-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

40M1.0-0000-00040
 GEAR BOX
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809211-010 ............................ Screw ...................................................................................................... 5

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

809407 .................................... Gear Box ................................................................................................ 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-3.1-2910

41
DRIVE MOTOR

M1775

MP-3.2-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

REV.1 04/02
42M1.0-0000-00042
 DRIVE MOTOR
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809408 .................................... Support ................................................................................................... 1

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

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-3.2-2910

REV.1 04/02
43
 Page intentionally left blank

Printed in Germany

44M1.0-0000-00044
 SECTION 4

Printed in Germany

45
ELECTRICAL PARTS

M1788

MP-4.0-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

46M1.0-0000-00046
 ELECTRICAL PARTS
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809436 .................................... Controller ............................................................................................... 1

2 ..................... 809231-002 ............................ Screw ...................................................................................................... 4
3 ..................... 809232-001 ............................ Washer ................................................................................................... 4
4 ..................... 809246 .................................... Support ................................................................................................... 1
5 ..................... 809243 .................................... Contactor ................................................................................................ 2
6 ..................... 809233-002 ............................ Nut .......................................................................................................... 4
7 ..................... 809172-001 ............................ Washer ................................................................................................... 4
8 ..................... 809231-003 ............................ Screw ...................................................................................................... 4
9 ..................... 809231-004 ............................ Screw ...................................................................................................... 2
10 ................... 809005-005 ............................ Washer ................................................................................................... 2
11 ................... 809004-005 ............................ Nut .......................................................................................................... 4
12 ................... 809005-002 ............................ Washer ................................................................................................... 4
13 ................... 809005-007 ............................ Washer ................................................................................................... 2
14 ................... 809416 .................................... Screw ...................................................................................................... 2
15 ................... 809417 .................................... Plate ....................................................................................................... 1
16 ................... 809418 .................................... Fuse ........................................................................................................ 2
17 ................... 809233-001 ............................ Nut .......................................................................................................... 7
18 ................... 809005-004 ............................ Washer ................................................................................................... 7
19 ................... 809232-003 ............................ Washer ................................................................................................... 6
20 ................... 809232-002 ............................ Washer ................................................................................................... 8
21 ................... 809241 .................................... Buffer ...................................................................................................... 4
22 ................... 809248 .................................... Relay ...................................................................................................... 2
23 ................... 809275-003 ............................ Support ................................................................................................... 2
24 ................... 809231-005 ............................ Screw ...................................................................................................... 1
25 ................... 809232-004 ............................ Washer ................................................................................................... 1
26 ................... 809275-002 ............................ Support ................................................................................................... 1
27 ................... 809275 .................................... Support ................................................................................................... 1
28 ................... 809419 .................................... Fuse ........................................................................................................ 1
29 ................... 809247 .................................... Fuse Holder ........................................................................................... 1
30 ................... 809240 .................................... Filter ........................................................................................................

OPTIONAL

31 ................... 809249 .................................... Programmer ........................................................................................... 1

32 ................... 809250-001 ............................ Connector .............................................................................................. 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-4.0-2910

47
ELECTRICAL PARTS

M1787

MP-4.0-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

48M1.0-0000-00048
 ELECTRICAL PARTS
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809004-005 ............................ Nut .......................................................................................................... 4

2 ..................... 809005-001 ............................ Washer ................................................................................................... 6
3 ..................... 809463 .................................... Pedal ...................................................................................................... 1
4 ..................... 809171-005 ............................ Screw ...................................................................................................... 1
5 ..................... 809464 .................................... Pedal Extension ..................................................................................... 1
6 ..................... 809465 .................................... Stop ........................................................................................................ 1
7 ..................... 809006-015 ............................ Screw ...................................................................................................... 8
8 ..................... 809005-002 ............................ Washer ................................................................................................... 4
9 ..................... 809060-001 ............................ Spring ..................................................................................................... 1
10 ................... 809171-006 ............................ Screw ...................................................................................................... 1
11 ................... 809467 .................................... Ball Joint ................................................................................................ 2
12 ................... 809171-007 ............................ Screw ...................................................................................................... 1
13 ................... 809468 .................................... Accelerator ............................................................................................. 1
14 ................... 809006-018 ............................ Screw ...................................................................................................... 1
15 ................... 809469 .................................... Lever ...................................................................................................... 1
16 ................... 809231-004 ............................ Screw ...................................................................................................... 1
17 ................... 809005-005 ............................ Washer ................................................................................................... 1
18 ................... 809276-002 ............................ Screw ...................................................................................................... 3
19 ................... 809006-017 ............................ Screw ...................................................................................................... 1
20 ................... 809069-009 ............................ Circlip ..................................................................................................... 2
21 ................... 809013-004 ............................ Spacer .................................................................................................... 2
22 ................... 809470 .................................... Hub ......................................................................................................... 1
23 ................... 809471 .................................... Shaft ....................................................................................................... 1
24 ................... 809211-006 ............................ Screw ...................................................................................................... 2
25 ................... 809472 .................................... Cam ........................................................................................................ 1
26 ................... 809473 .................................... Potentiometer ......................................................................................... 1
27 ................... 809208-001 ............................ Nut .......................................................................................................... 3
28 ................... 809210-001 ............................ Washer ................................................................................................... 1
29 ................... 809474 .................................... Support ................................................................................................... 1
30 ................... 809171-008 ............................ Screw ...................................................................................................... 1
31 ................... 809475 .................................... Plate ....................................................................................................... 1
32 ................... 809476 .................................... Box ......................................................................................................... 1
33 ................... 809477 .................................... Switch ..................................................................................................... 1
34 ................... 809478 .................................... Support ................................................................................................... 1
35 ................... 809211-007 ............................ Screw ...................................................................................................... 2

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-4.0-2910

49
ELECTRICAL PARTS

M1789

MP-4.0-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

50M1.0-0000-00050
 ELECTRICAL PARTS
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 .....................
809479-001 ............................ Cable ...................................................................................................... 1
2 .....................
809423 .................................... Battery Connector .................................................................................. 2
3 .....................
809004-012 ............................ Nut .......................................................................................................... 2
4 .....................
809479-002 ............................ Cable ...................................................................................................... 1
5 .....................
809421 .................................... Handle .................................................................................................... 1
6 .....................
809006-017 ............................ Screw ...................................................................................................... 2
7 .....................
809005-001 ............................ Washer ................................................................................................... 4
8 .....................
809005-019 ............................ Screw ...................................................................................................... 2
9 .....................
809480-001 ............................ Battery 285 Ah ....................................................................................... 1
809480-002 ............................ Battery 315 Ah ....................................................................................... 1
809480-003 ............................ Battery 280 Ah ....................................................................................... 1
809480-004 ............................ Battery 320 Ah ....................................................................................... 1
809480-005 ............................ Battery 380 Ah ....................................................................................... 1
809480-006 ............................ Battery 420 Ah ....................................................................................... 1
809480-007 ............................ Battery 500 Ah ....................................................................................... 1
10 ................... 809481-001 ............................ Battery Tray ............................................................................................. 1
(285/315 Ah)
809481-002 ............................ Battery Tray ............................................................................................. 1
(280,320,380,420,500 Ah)
11 ................... 809486-001 ............................ Plug ........................................................................................................ 1
12 ................... 809482 .................................... Joystick ................................................................................................... 1
13 ................... 809224-003 ............................ Push ....................................................................................................... 1
14 ................... 809486-002 ............................ Plug ........................................................................................................ 3
15 ................... 809483 .................................... Lence ...................................................................................................... 2
16 ................... 809484 .................................... Lamp ...................................................................................................... 2
17 ................... 809485 .................................... Light ........................................................................................................ 2
18 ................... 809224-001 ............................ Push ....................................................................................................... 1
19 ................... 809225 .................................... Contact ................................................................................................... 1
20 ................... 809226 .................................... Keyswitch ............................................................................................... 1
21 ................... 809430 .................................... Discharge Meter .................................................................................... 1
22 ................... 809487 .................................... Push ....................................................................................................... 1
23 ................... 809262 .................................... Contact ................................................................................................... 1
24 ................... 809259 .................................... Horn ........................................................................................................ 1
25 ................... 809432 .................................... Support ................................................................................................... 1
26 ................... 809276-004 ............................ Screw ...................................................................................................... 2
27 ................... 809264 .................................... Switch ..................................................................................................... 1
28 ................... 809142-003 ............................ Washer ................................................................................................... 2
29 ................... 809005-016 ............................ Washer ................................................................................................... 2
30 ................... 809231-007 ............................ Screw ...................................................................................................... 2

OPTIONAL

31 ................... 809006-019 ............................ Screw ...................................................................................................... 4

32 ................... 809005-002 ............................ Washer ................................................................................................... 4
33 ................... 809013-016 ............................ Spacer .................................................................................................... 4
34 ................... 809258 .................................... Power Control Unit ................................................................................. 1
35 ................... 809242-004 ............................ Fuse ........................................................................................................ 1
36 ................... 809242-005 ............................ Fuse ........................................................................................................ 1
37 ................... 809231-005 ............................ Screw ...................................................................................................... 2
38 ................... 809232-004 ............................ Washer ................................................................................................... 2
39 ................... 809243 .................................... Contactor ................................................................................................ 1
40 ................... 809257-002 ............................ Buzzer .................................................................................................... 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-4.0-2910

51
WIRING HARNESS

Instrument Board
Armaturenbrett
Tablleau de bord

Accelerator
Fahrgeber
Accelerateur

Instrument Board
Armaturenbrett
Tablleau de bord

M1790

MP-4.11-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

52M1.0-0000-00052
 WIRING HARNESS
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809433-001 ............................ Cable ...................................................................................................... 1

2 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
3 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
4 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
5 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
6 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
7 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
8 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
9 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
10 ................... 809433-002 ............................ Cable ...................................................................................................... 1
11 ................... 809433-002 ............................ Cable ...................................................................................................... 1
12 ................... 809433-002 ............................ Cable ...................................................................................................... 1
13 ................... 809488 .................................... Cable ...................................................................................................... 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-4.11-2910

53
WIRING HARNESS

Instrument Board
Armaturenbrett
Tablleau de bord

Accelerator
Fahrgeber
Accelerateur

Instrument Board
Armaturenbrett
Tablleau de bord

M1791

MP-4.11-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

54M1.0-0000-00054
 WIRING HARNESS
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809433-001 ............................ Cable ...................................................................................................... 1

2 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
3 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
4 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
5 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
6 ..................... 809433-001 ............................ Cable ...................................................................................................... 1
7 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
8 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
9 ..................... 809433-002 ............................ Cable ...................................................................................................... 1
10 ................... 809433-002 ............................ Cable ...................................................................................................... 1
11 ................... 809433-002 ............................ Cable ...................................................................................................... 1
12 ................... 809433-002 ............................ Cable ...................................................................................................... 1
13 ................... 809433-004 ............................ Cable ...................................................................................................... 1
14 ................... 809433-004 ............................ Cable ...................................................................................................... 1
15 ................... 809433-004 ............................ Cable ...................................................................................................... 1
16 ................... 809433-004 ............................ Cable ...................................................................................................... 1
17 ................... 809433-004 ............................ Cable ...................................................................................................... 1
18 ................... 809489 .................................... Cable ...................................................................................................... 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-4.11-2910

55
 Page intentionally left blank

Printed in Germany

56M1.0-0000-00056
 SECTION 6

Printed in Germany

57
STEERING

M1785

MP-6.4-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

58M1.0-0000-00058
 STEERING
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809284-002 ............................ Plug ........................................................................................................ 1

2 ..................... 809371 .................................... Knob ....................................................................................................... 1
3 ..................... 809372 .................................... Steering Wheel ...................................................................................... 1
4 ..................... 809006-029 ............................ Screw ...................................................................................................... 3
5 ..................... 809005-005 ............................ Washer ................................................................................................... 3
6 ..................... 809005-009 ............................ Washer ................................................................................................... 1
7 ..................... 809457-001 ............................ Shaft ....................................................................................................... 1
8 ..................... 809373-001 ............................ Woodruff Key .......................................................................................... 1
9 ..................... 809296-016 ............................ Pin .......................................................................................................... 2
10 ................... 809458 .................................... Handle .................................................................................................... 1
11 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 6
12 ................... 809459-001 ............................ Support ................................................................................................... 1
13 ................... 809171-004 ............................ Screw ...................................................................................................... 1
14 ................... 809069-006 ............................ Circlip ..................................................................................................... 4
15 ................... 809460 .................................... Cardan Shaft .......................................................................................... 1
16 ................... 809457-002 ............................ Shaft ....................................................................................................... 1
17 ................... 809373-002 ............................ Woodruff Key .......................................................................................... 1
18 ................... 809375-002 ............................ Circlip ..................................................................................................... 2
19 ................... 809459-002 ............................ Support ................................................................................................... 1
20 ................... 809142-001 ............................ Washer ................................................................................................... 2
21 ................... 809005-003 ............................ Washer ................................................................................................... 2
22 ................... 809276-019 ............................ Screw ...................................................................................................... 2
23 ................... 809377 .................................... Spacer .................................................................................................... 4
24 ................... 809376-001 ............................ Gear ........................................................................................................ 1
25 ................... 809069-001 ............................ Circlip ..................................................................................................... 2
26 ................... 809379-001 ............................ Link Extended ........................................................................................ 1
27 ................... 809004-002 ............................ Nut .......................................................................................................... 1
28 ................... 809382 .................................... Washer ................................................................................................... 1
29 ................... 809459-003 ............................ Support ................................................................................................... 1
30 ................... 809296-015 ............................ Pin .......................................................................................................... 1
31 ................... 809305-007 ............................ Bushing .................................................................................................. 1
32 ................... 809461 .................................... Gear ........................................................................................................ 1
33 ................... 809005-008 ............................ Washer ................................................................................................... 6
34 ................... 809376-003 ............................ Gear ........................................................................................................ 1
35 ................... 809378 .................................... Chain ...................................................................................................... 1
36 ................... 809380-001 ............................ Steering Clutch ...................................................................................... 1
37 ................... 809373-003 ............................ Woodruff Key .......................................................................................... 2
38 ................... 809462-001 ............................ Spacer .................................................................................................... 4
39 ................... 809462-002 ............................ Spacer .................................................................................................... 6
40 ................... 809278-010 ............................ Support ................................................................................................... 1
41 ................... 809005-004 ............................ Washer ................................................................................................... 4
42 ................... 809006-007 ............................ Screw ...................................................................................................... 4
43 ................... 809457-003 ............................ Shaft ....................................................................................................... 1
44 ................... 809376-004 ............................ Gear ........................................................................................................ 1
45 ................... 809145 .................................... Chain ...................................................................................................... 1
46 ................... 809144 .................................... Link Extended ........................................................................................ 2
47 ................... 809385 .................................... Chain Adjuster ....................................................................................... 1

OPTIONAL

48 ................... 809231-007 ............................ Screw ...................................................................................................... 2

49 ................... 809005-016 ............................ Washer ................................................................................................... 2
50 ................... 809142-003 ............................ Washer ................................................................................................... 2
51 ................... 809256 .................................... Switch ..................................................................................................... 1
52 ................... 809394 .................................... Support ................................................................................................... 1
53 ................... 809431 .................................... Hose Clamp ........................................................................................... 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-6.4-2910

REV.1 04/02
59
STEERING

M1786

MP-6.4-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

60M1.0-0000-00060
 STEERING
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809284-002 ............................ Plug ........................................................................................................ 1

2 ..................... 809371 .................................... Knob ....................................................................................................... 1
3 ..................... 809372 .................................... Steering Wheel ...................................................................................... 1
4 ..................... 809006-029 ............................ Screw ...................................................................................................... 3
5 ..................... 809005-005 ............................ Washer ................................................................................................... 3
6 ..................... 809005-009 ............................ Washer ................................................................................................... 1
7 ..................... 809491 .................................... Shaft ....................................................................................................... 1
8 ..................... 809373-001 ............................ Woodruff Key .......................................................................................... 1
9 ..................... 809006-026 ............................ Screw ...................................................................................................... 1
10 ................... 809014-005 ............................ Bearing Ball ........................................................................................... 2
11 ................... 809069-005 ............................ Circlip ..................................................................................................... 1
12 ................... 809458 .................................... Handle .................................................................................................... 1
13 ................... 809492-001 ............................ Support ................................................................................................... 1
14 ................... 809171-004 ............................ Screw ...................................................................................................... 1
15 ................... 809299 .................................... Circlip ..................................................................................................... 1
16 ................... 809005-016 ............................ Washer ................................................................................................... 19
17 ................... 809003-007 ............................ Buffer ...................................................................................................... 4
18 ................... 809004-009 ............................ Nut .......................................................................................................... 8
19 ................... 809006-025 ............................ Screw ...................................................................................................... 3
20 ................... 809135-002 ............................ Flange .................................................................................................... 1
21 ................... 809136 .................................... Motor ...................................................................................................... 1
22 ................... 809060-006 ............................ Spring ..................................................................................................... 2
23 ................... 809388 .................................... Brush Kit ................................................................................................. 1
24 ................... 809373-004 ............................ Woodruff Key .......................................................................................... 1
25 ................... 809389 .................................... Motor ...................................................................................................... 1
26 ................... 809390 .................................... Gear Box ................................................................................................ 1
27 ................... 809006-006 ............................ Screw ...................................................................................................... 2
28 ................... 809005-003 ............................ Washer ................................................................................................... 2
29 ................... 809492-002 ............................ Support ................................................................................................... 1
30 ................... 809005-004 ............................ Washer ................................................................................................... 4
31 ................... 809006-014 ............................ Screw ...................................................................................................... 4
32 ................... 809391 .................................... Gear ........................................................................................................ 1
33 ................... 809005-026 ............................ Washer ................................................................................................... 1
34 ................... 809005-027 ............................ Washer ................................................................................................... 1
35 ................... 809005-002 ............................ Washer ................................................................................................... 1
36 ................... 809006-012 ............................ Screw ...................................................................................................... 1
37 ................... 809145 .................................... Chain ...................................................................................................... 1
38 ................... 809144 .................................... Link Extended ........................................................................................ 2
39 ................... 809385 .................................... Chain Adjuster ....................................................................................... 1
40 ................... 809231-007 ............................ Screw ...................................................................................................... 4
41 ................... 809142-003 ............................ Washer ................................................................................................... 4
42 ................... 809264 .................................... Switch ..................................................................................................... 2
43 ................... 809392 .................................... Support ................................................................................................... 1
44 ................... 809006-027 ............................ Screw ...................................................................................................... 2
45 ................... 809172-001 ............................ Washer ................................................................................................... 2
46 ................... 809393-001 ............................ Cam ........................................................................................................ 1
47 ................... 809393-002 ............................ Cam ........................................................................................................ 1
48 ................... 809231-005 ............................ Screw ...................................................................................................... 4

OPTIONAL

49 ................... 809231-007 ............................ Screw ...................................................................................................... 2

50 ................... 809005-016 ............................ Washer ................................................................................................... 2
51 ................... 809142-003 ............................ Washer ................................................................................................... 2
52 ................... 809256 .................................... Switch ..................................................................................................... 1
53 ................... 809394 .................................... Support ................................................................................................... 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-6.4-2910

61
 Page intentionally left blank

Printed in Germany

62M1.0-0000-00062
 SECTION 7

Printed in Germany

63
LIFT STRUCTURE

M1769

MP-7.8-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

64M1.0-0000-00064
 LIFT STRUCTURE
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809454 .................................... Screw ...................................................................................................... 6

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

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-7.8-2910

REV. 1 04/02
65
 Page intentionally left blank

Printed in Germany

66M1.0-0000-00066
 SECTION 8

Printed in Germany

67
LIFT CYLINDER

M1768

MP-8.4-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

REV.1 04/02
68M1.0-0000-00068
 LIFT CYLINDER
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809314 .................................... Cylinder Tube ......................................................................................... 1

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

809033-001 ............................ Seal Kit ................................................................................................... 1

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

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-8.4-2910

REV. 1 04/02
69
 Page intentionally left blank

Printed in Germany

70M1.0-0000-00070
 SECTION 10

Printed in Germany

71
BATTERY TROLLEY

M1783

MP-10.0-2910 MP-RT3020-Rev.2-GB 04/02 • Printed in Germany

72M1.0-0000-00072
 BATTERY TROLLEY
INDEX PART NUMBER PART NAME NUMBER REQUIRED

1 ..................... 809452 .................................... 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

809453 .................................... Chassis Assembly ................................................................................. 1

Always Specify Model & Serial Number

MP-RT3020-Rev.2-GB 04/02 • Printed in Germany MP-10.0-2910

73
 Page intentionally left blank

Printed in Germany

74M1.0-0000-00074
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: 812700-006