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SERVICE MANUAL Machine: A-86 Manual No: 005940 Edition:: 2001A

The content of this service manual is protected by copyright law and may not be copied, fully or in part, without written permission.

The material has undergone careful examination with regard to correctness. Subject to alteration.

In the event of inconsistent information in the Swedish and translated editions, it is the Swedish edition that applies.

Modifications and updates will be distributed via ATLET AB Service Manual Change.

Approved 2002-05-16: John Yeeles Technical After Sales Support Martin Hansen Technical Documentation ATLET SERVICE MANUAL

Table of Contents Sida 2 (4) Edition 2001A

1 General information and technical dataon 1.1 Introduction .................................................................................................................................................. 1.1 1.2 General information A-86 series .................................................................................................................. 1.2 1.3 How to use the manual ................................................................................................................................ 1.3 1.4 Tips before next step.................................................................................................................................... 1.4 1.5 Data A-86 ..................................................................................................................................................... 1.8 1.6 Dimensions and weights ............................................................................................................................ 1.12 1.7 Component specification ............................................................................................................................ 1.14 1.8 Tightening torque ...................................................................................................................................... 1.16 1.9 Lubrication chart......................................................................................................................................... 1.19 1.10 Recommended oil and grease types........................................................................................................ 1.22 1.11 Colour of the truck in accordance with NCS colour codes ....................................................................... 1.23 1.12 Colour codes for Atlet’s wiring diagrams .................................................................................................. 1.24 1.13 Designations for electrical components ................................................................................................... 1.25 1.14 Technical abbreviations ........................................................................................................................... 1.26 1.15 Recommended replacement .................................................................................................................... 1.27 Edition 2001A

2 Special tools 2.1 List of tools ................................................................................................................................................... 2.1 Edition 2001A

3 Service 3.1 Introduction .................................................................................................................................................. 3.1 3.2 Service inspection list................................................................................................................................... 3.2 3.3 Code explanations ....................................................................................................................................... 3.7 Edition 2001A

4 Chassis 4.1 Introduction .................................................................................................................................................. 4.1 4.2 Tightening torque ......................................................................................................................................... 4.2 4.3 Caster wheel ................................................................................................................................................ 4.4 4.4 Panels .......................................................................................................................................................... 4.6 4.5 Replacing the battery rollers ........................................................................................................................ 4.7 4.6 Replacing the load wheel, bogie wheel ........................................................................................................ 4.8 4.7 Replacing the load wheel, single wheel ....................................................................................................... 4.9

ATLET SERVICE MANUAL

Table of Contents Sida 3 (4) Edition 2001A

5 Drive unit 5.1 Introduction .................................................................................................................................................. 5.1 5.2 Dismantling and assembling the drive unit................................................................................................... 5.2 5.3 Drive motor................................................................................................................................................... 5.5 5.4 Reconditioning the motor ............................................................................................................................. 5.6 5.5 Insulation test ............................................................................................................................................. 5.10 5.6 Gearbox ..................................................................................................................................................... 5.11 5.7 Trouble shooting chart ............................................................................................................................... 5.12 Edition 2001A

6 Mast 6.1 Introduction .................................................................................................................................................. 6.1 6.2 Dismantling and assembling the masts, general.......................................................................................... 6.2 6.3 Mast system to: A -15000 ............................................................................................................................ 6.3 6.4 Mast system from: A -15000 ...................................................................................................................... 6.14 6.5 Fork carriage .............................................................................................................................................. 6.22 6.6 Forks .......................................................................................................................................................... 6.28 6.7 Checking the lift chains .............................................................................................................................. 6.31 6.8 Straddle lift ................................................................................................................................................. 6.33 6.9 Side stabilisers ........................................................................................................................................... 6.37 6.10 Lift cylinders ............................................................................................................................................. 6.42 Edition 2001A

7 Steering 7.1 Introduction .................................................................................................................................................. 7.1 7.2 Mechanical steering ..................................................................................................................................... 7.5 7.3 Electronic steering (ACC)............................................................................................................................. 7.6 Edition 2001A

8 Hydraulic system 8.1 Functional description .................................................................................................................................. 8.1 8.2 Hydraulic system – general regulations ....................................................................................................... 8.3 8.3 Hydraulic oil, changing/draining ................................................................................................................... 8.8 8.4 Air filter, replacing ...................................................................................................................................... 8.10 8.5 Filter insert, replacing ................................................................................................................................. 8.11 8.6 Valves, AJN / ASN / ATF ........................................................................................................................... 8.12 8.7 Hydraulic motor ASN / ATF........................................................................................................................ 8.19 8.8 Hydraulic motor AJN / ATF ........................................................................................................................ 8.21 8.9 Stabiliser cylinders ASN / AJN ................................................................................................................... 8.23 8.10 Hydraulic diagram .................................................................................................................................... 8.26

ATLET SERVICE MANUAL

Table of Contents Sida 4 (4) Edition 2001A

9 Lift cylinders 9.1 Introduction .................................................................................................................................................. 9.1 9.2 Free lift cylinder TFV / DTFV........................................................................................................................ 9.2 9.3 Lift cylinder TV/ TFV/ DTFV (not 160) ......................................................................................................... 9.6 9.4 Lift cylinder TV/ TFV/ DTFV (160) ............................................................................................................. 9.10 9.5 Lift cylinder 100 DT / 125 DT to: A -11508 ................................................................................................. 9.13 9.6 Lift cylinder 100 DT / 125 DT from: A -11509............................................................................................. 9.16 9.7 Lift cylinder 100 T / 125 T........................................................................................................................... 9.19 9.8 Lift cylinder 160 T ....................................................................................................................................... 9.21 9.9 Bleeding the cylinders ................................................................................................................................ 9.23 Edition 2001A

10 Electrical system 10.1 Safety procedures .................................................................................................................................... 10.1 10.2 Battery maintenance ................................................................................................................................ 10.2 10.3 Drive motor............................................................................................................................................... 10.3 10.4 Fork drive motor, ATF truck ..................................................................................................................... 10.5 10.5 Speed controller ....................................................................................................................................... 10.8 10.6 Sigma Transistor - System TR 250 CS .................................................................................................. 10.11 10.7 Curtis 1207 ............................................................................................................................................. 10.21 10.8 Side stabilisers ....................................................................................................................................... 10.34 10.9 Wiring diagram ....................................................................................................................................... 10.36 Edition 2001A

11 Brake system 11.1 Hydraulic brake ........................................................................................................................................ 11.1 11.2 Electric brake ........................................................................................................................................... 11.8

ATLET SERVICE MANUAL

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

General information and technical dataon 1.1 Introduction................................................................................................................... 1.1 1.2 General information A-86 series ................................................................................. 1.2 1.3 How to use the manual ................................................................................................ 1.3 1.3.1 History ..........................................................................................................................1.3 1.3.2 Symbol key ...................................................................................................................1.3 1.4 Tips before next step ................................................................................................... 1.4 1.4.1 Lifting points .................................................................................................................1.4 1.4.2 Safety instructions .........................................................................................................1.5 1.4.3 Safety risks when working on fork trucks ....................................................................1.5 1.4.4 Environmentally hazardous waste – environment ........................................................1.6 1.4.5 Handling ........................................................................................................................1.6 1.4.6 Trouble shooting ...........................................................................................................1.7 1.5 Data A-86 ....................................................................................................................... 1.8 1.6 Dimensions and weights ........................................................................................... 1.12 1.6.1 Dimensions AJN / ASN ..............................................................................................1.12 1.6.2 Dimensions ATF .........................................................................................................1.13 1.7 Component specification........................................................................................... 1.14 1.8 Tightening torque ...................................................................................................... 1.16 1.8.1 Conversion table .........................................................................................................1.17 1.8.2 Bolt types and tensile grades ......................................................................................1.17

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

1.9 Lubrication chart ........................................................................................................ 1.19 1.9.1 Lubrication chart AJN / ASN ..................................................................................... 1.19 1.9.2 Lubrication chart ATF ................................................................................................ 1.20 1.9.3 Symbol explanations, lubrication chart ...................................................................... 1.21 1.10 Recommended oil and grease types ...................................................................... 1.22 1.11 Colour of the truck in accordance with NCS colour codes.................................. 1.23 1.12 Colour codes for Atlet’s wiring diagrams .............................................................. 1.24 1.13 Designations for electrical components ................................................................ 1.25 1.14 Technical abbreviations .......................................................................................... 1.26 1.15 Recommended replacement ................................................................................... 1.27

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

General information and technical dataon

1.1

Edition 2001A

1 General information and technical dataon 00000000

1.1

Introduction This manual describes the service procedures for ATLET Stand on stackers in the A-86 series. Use the manual for quick and correct service of respective truck models.

You may find contradictions in the manual compared to the models supplied due to optional designs and the like.

Warning!

If the truck is rebuilt after delivery or supplemented in such a manner that safety may be affected, ATLET AB or its authorised representative should be contacted.

The electrical system must never be rewired in any form after delivery without written authorisation from ATLET AB, since this may change the measured and applicable EMC. The content of this service manual is protected by copyright law and may not be copied, fully or in part, without written permission. The material has undergone careful examination with regard to correctness. Subject to alteration. In the event of inconsistent information in the Swedish and translated editions, it is the Swedish edition that applies.

Modifications and updates will be distributed via ATLET AB Service Manual Change.

SM_A_01_e_2001a.fm

Introduction

ATLET SERVICE MANUAL

1.2

1.2

General information and technical dataon

General information A-86 series The stand-on stacker trucks in the A-86 series include AJN, ASN and ATF.

ATLET SERVICE MANUAL

General information A-86 series

General information and technical dataon

1.3

1.3

How to use the manual The manual is arranged according to the same principles as ATLET’s spare part catalogues, i.e. a system consists of 12 sections, where sections 4 -12 contain information limited to a specific part of the truck. For example, Masts (section 6) and Hydraulic System (section 8). Sections 1 - 3 in this manual contain more comprehensive information regarding technical data, general service, instructions and tools. The main principle for extra accessories is to place them under the respective sections. Otherwise they are placed under section 12 “Miscellaneous”.

For this reason section 12 is not always included in the Service Manual.

For specific problems or information about procedures, look in the main index for the correct section.

1.3.1

History

The following modifications affect the service procedure.

Table 1.1 Date

Chassis no.

13001

Event Control System Sigma -> Curtis 1207 (upgrading of drive motor fuse)

9120

Mechanical steering replaced

9640

Power steering is introduced as an alternative

9201

The stabiliser cylinder has a different design 11506

Fork carriage ATF has a different design

15000

New mast system introduced with designation 160

9105

1.3.2

Hydraulic valve replaced

Symbol key

Warning!

Used with risk of personal injury.

Important!

Used with risk of damage to machine.

Note!

Used for general observation.

How to use the manual

ATLET SERVICE MANUAL

1.4

1.4

General information and technical dataon

Tips before next step 0

1.4.1

Lifting points

C

A

B

D SM 067.1

Figure 1.1 Lifting points

ATLET SERVICE MANUAL

Tips before next step

General information and technical dataon

1.5

In figure 1.1 it shows where the permitted lifting points are placed on the truck.

Lifting points B and D are marked with decals representing a lifting hook. The lifting holes in the outer mast (point A) should be used when lifting masts or machines with free-view masts.

The lifting strap is placed round the upper mast strut (point C) when lifting other machines with mast type T, DT. Lifting point for jack (point D).

Warning!

The machine must never be lifted from the overhead guard.

1.4.2

Safety instructions

When the truck is lifted using a jack, make sure you secure it with blocks. The truck must not rest on the jack, while work is carried out.

Ensure that straps, wires or chains have a sufficient lifting capacity before lifting the truck. Pull out the battery plug before working on the electrical system.

Ensure that the drive wheel runs free of the floor before trouble shooting.

The system should not be pressurised, e.g. the pump motor shut off and the forks down, when dismantling parts of the hydraulic system.

1.4.3

Safety risks when working on fork trucks

Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle.

A general rule is to always implement preventive measures that are adapted to the type of vehicle to be worked on. The general rules below must always be observed: • Smoking or naked flames are strictly forbidden as there is a risk of explosion in the vicinity of batteries and while working on gas equipped vehicles.

• The battery should always be protected during grinding work.

• The fire regulations for the building should also be observed.

The drive wheel should always be lifted up free from the floor during service work to prevent the vehicle from moving. The vehicle must not rest solely on the jack, but must be secured by some form of blocking.

To prevent injuries caused by crushing, the battery plug should always be pulled out when working around the mast, reach carriage and power pack on electric Reach Trucks. The mast, reach carriage and power pack can be actuated due to an electrical fault or a mistake while working. The battery plug may only be connected while trouble shooting, and when the greatest of care is exercised, (with the truck raised).

Tips before next step

ATLET SERVICE MANUAL

1.6

General information and technical dataon

Warning!

Standing on the reach carriage between the mast and battery partition with the current connected to the truck can result in fatal injury!

When working on and around the mast and power pack, they must be locked by using the mast lock, wooden blocks or some other appropriate means.

No other persons should be in the vicinity of the truck when it is test run in conjunction with repair work, in view of the risk of accidents or near-accidents from the truck making an unexpected manoeuvre.

When working on the gas equipment on gas driven vehicles the gas system should be emptied first, if possible, by shutting the main tap and running the motor or equipment until the system is empty and stops.

Escaping gas is heavier than air and has a tendency to collect in cavities, and can be ignited by sparks or a naked flame. The machine should therefore be ventilated with compressed air before service work is begun. Ventilation should also be carried out after repairs before the motor or another unit is started, since sparks from the starter or relays can cause explosions.

The system should not be pressurised, e.g. the pump motor shut off and the forks down, when dismantling parts of the hydraulic system.

All metal objects such as watches and rings should be removed when working on the electrical system, or in its immediate vicinity. A short-circuit from such objects can result in serious burn injuries.

1.4.4

Environmentally hazardous waste – environment

Atlet AB takes care of the environment. Waste material in conjunction with repairs, maintenance, cleaning, or scrapping, should be collected and disposed of in an environment-friendly way and in accordance with the directives of respective countries. Such work must only be carried out in areas intended for this purpose.

Environmentally hazardous waste, such as oil filters, batteries, hydraulic hoses and electronics, can have a negative effect on the environment, or health, if handled incorrectly. Recyclable material should be taken care of by specialised authorities.

1.4.5

Handling

Make sure that you have all the essential tools close at hand before starting work.

Before cabling or other electrical components are disconnected, check the colour codes and check for damage to cables or connections.

When complex components are repaired and dismantled, make sure that you have good control of the different component parts to avoid the risk of confusion.

ATLET SERVICE MANUAL

Tips before next step

General information and technical dataon

1.7

When repairing or maintaining sensitive components, make sure that you use clean tools and work on a clean work surface.

Dismantle, inspect and adjust components according to the prescribed routines. See respective sections for detailed information.

Make sure that gaskets and O-rings, etc. are replaced with new parts each time they are dismantled.

Always use ATLET’s original spare parts.

Use the screws and bolts specified in the spare parts catalogue. Tighten according to instructions. In those cases where the tightening torque is not specified, refer to the table of standard tightening torque in section 1.8.

1.4.6

Trouble shooting

When you suspect a faulty component, do not replace it immediately. First check the surrounding equipment and carry out complete trouble shooting routines. Make sure you know the reason for the fault before replacing a component.

Tips before next step

ATLET SERVICE MANUAL

1.8

1.5

General information and technical dataon

Data A-86 Table 1.2 Truck type

Designations

Load capacity

Standard combinations

A

Junior, Senior

ATF

Junior, Senior

A

Standard

ATF

Telescopic forks

JN

Junior

SN

Senior

AJN

1000 kg, 1250 kg, 1600 kg

ASN

1250 kg, 2000 kg, 1600 kg

ATF

1000 kg

AJN 1000

ST

AJN 1250

ST, SDT, SDT-S, STV, STFV, SDTFV, STV-S, STFVS, SDTFV-S, STV-H, STFV-H, SDTFV-H, BTV, BTFV, BDTFV.

ASN 1250

ST, SDT, SDT-S, STV, STFV, SDTFV, STV-S, STFVS, SDTFV-S, STV-H, STFV-H, SDTFV-H, BTV, BTFV, BDTFV.

AJN 1600 ASN 1600

ST, STV, STFV, SDTFV, ST-H, STV-H, STFV-H, SDTFV-H, SDTFV-S

ASN 2000 ASN 1600*

STV, STFV, SDTFV, STV-S, SDTFV-S, STV-H, STFV-H, SDTFV-H, BTV, BTFV, BDTFV.

ATF 1000 Junior Senior

BT, BTFV, BDT, BDTFV

* Changed to ASN 1620

ATLET SERVICE MANUAL

Data A-86

General information and technical dataon

1.9

Type designations (example):

125 STV

S

360 / 225 / 40 / ...

...

Load capacity/10 Narrow track Wide track

S B

Telescopic mast Telescopic free lift mast Dual telescopic mast Dual telescopic free lift mast

T TF DT DTF

Free visibility mast V Stabilisers S Adjustable straddle legs H Lifting height in cm Battery Ah/5 Battery charger Ampere Model type AJN, ASN, ATF AJN = Junior ASN = Senior

SM 068.1e

Figure 1.2 Type designation

Data A-86

ATLET SERVICE MANUAL

1.10

General information and technical dataon

ATLET AB MÖLNLYCKE SWEDEN MODELL MODEL MODELL

125 STV 360 ASN

Model

ASN 10568 S

Serial No: Model, Serial No (S=Special)

1995 34-6

Manufactured year, week and duration of guarentee in months. (under the circumstanses that the guarantee service instructions have been followed).

MODELE

SERIE NR. SERIAL NO. SERIEN NR. NOMERO DESERIE

TILLV. ÅR YEAR OF MANUF. BAUJAHR AN DE FABR

TILLÅTEN LAST ACTUAL CAPACITY WIRKLICHE TRAGFÄHIGKEIT CAPACITE EFFECTIVE

TYNGDPUNKTSAVSTÅND

LYFTHÖJD

LOAD CENTRE DISTANCE

LIFTHEIGHT

LASTSCHWERPUNKT

HUBHÖHE

DISTANCE DE CENTRE HAUTEUR DE LEVEE

3600 3600

600 500

1250 1250

BATTERISPÄNNING BATTERY VOLTAGE BATTERIESPANNUNG

VOLT-DC

24

TENSION DE LA BATTERIE

KG

VIKT UTAN BATTERI WEIGHT WITHOUT BATTERY GEWICHT OHNE BATTERIE

1150

MASSE SANS BATTERIE

MINSTA BATTERIVIKT MINIMUM BATTERY WEIGHT MINDESTGEWICHT DER BATTERIE

370

KG

MASSE MINIMAL DE LA BATTERIE

KG

MAXIMAL BATTERIVIKT MAXIMUM BATTERY WEIGHT HÖCHSTGEWICHT DER BATTERIE

540

MASSE MAXIMAL DE LA BATTERIE

p2A 73.3e

Figure 1.3 Type designation

ATLET SERVICE MANUAL

Data A-86

General information and technical dataon

1.11

Serial No:

SM 0 69.1e

Figure 1.4 The serial number is stamped on the left side of the mast

Data A-86

ATLET SERVICE MANUAL

1.12

1.6

General information and technical dataon

Dimensions and weights 0

1.6.1

Dimensions AJN / ASN

5 B

270

H3 H4 H5

H6

R2

H1 H2

L2 L3 L4

L1 L

B1 V SM 070.1

Figure 1.5 AJN / ASN

ATLET SERVICE MANUAL

Dimensions and weights

General information and technical dataon

Dimensions ATF

B1 V B2 B

1.6.2

1.13

U

L1

H2

270

H3 H4 H5

H6

R2

H1 H7

L2 L3 L4

L1 L

Figure 1.6 ATF

Dimensions and weights

ATLET SERVICE MANUAL

1.14

1.7

General information and technical dataon

Component specification Table 1.3 Drive motor (See also section 5, Drive motor) Output standard

1.1 kW

Table 1.4 Gearbox (See also section 5, Gearbox) Gear ratio (standard)

11:1

Oil volume

0.75 litres

Table 1.5 Hydraulic system Max pressure

15 MPa (=150 kp/cm²)

Table 1.6 Hydraulic unit (motor and pump) Senior (See also section 8, Hydraulic unit) Output

4.5 kW

Table 1.7 Hydraulic unit (motor and pump) Junior (See also section 8, Hydraulic unit) Output

3.8 kW

Table 1.8 Control system for motor to machine number 13000 Type TR250 CS Low frequency

Transistor

Voltage

24 V

ATLET SERVICE MANUAL

Component specification

General information and technical dataon

1.15

Table 1.9 Control system for motor from machine number 13001 Type 1207 High frequency

Transistor

Voltage

24 V

Table 1.10 Fuses Control fuses 2 pcs.

8A

Pump motor fuse 1 pcs.

250 A

Drive motor fuse 1 pcs. to: A-13000

100 A

Drive motor fuse 1 pcs. from: A-13001

160 A

Component specification

ATLET SERVICE MANUAL

1.16

1.8

General information and technical dataon

Tightening torque 0

Table 1.11 DIM

Tensile grade 4,6

8,8

10,9

12,9

Nm

Nm

Nm

Nm

M4

1,1

2,9

4,0

4,9

M5

2,2

5,7

8,1

9,7

M6

3,7

9,8

14

17

M8

8,9

24

33

40

M10

17

47

65

79

M12

30

81

114

136

M14

48

128

181

217

M16

74

197

277

333

M18

103

275

386

463

M20

144

385

541

649

The tightening torque in the table 1.11 above are standard values. In some cases a specific tightening torque is specified in respective sections. If no tightening torque is specified in the service instructions, the values shown in the table 1.11 above apply.

Table 1.12 Tightening torque: Pipe thread / metric thread: Metric fine thread M10 x 1

Whitworth pipe thread G 1/8"

M12 x 1.5

MA (Nm) with

MA (Nm) with elastic

25

10

30

20

M14 x 1.5

G 1/4"

50

30

M16 x 1.5

G 3/8"

80

35

90

40

130

50

M22 x 1.5

150

60

M26 x 1.5

250

70

250

80

250

90

M18 x 1.5 M20 x 1.5

M27 x 1.5 M27 x 2

ATLET SERVICE MANUAL

G 1/2"

G 3/4"

Tightening torque

General information and technical dataon

1.17

Table 1.12 Tightening torque: Pipe thread / metric thread: Metric fine thread

Whitworth pipe thread G 1"

M33 x 2

MA (Nm) with

MA (Nm) with elastic

350

140

400

140

M42 x 2

G 11/4"

600

240

M48 x 2

G 11/2"

800

300

1.8.1

Conversion table

Table 1.13 Newton metre (Nm)

Kilopond metre (kpm)

Poundforce inch (lbg x in)

Poundforce foot (lbf x ft)

1

0,10

8,85

0,74

9,81

1

86,80

7,23

0,11

0,01

1

0,08

1,36

0,14

12,00

1

1.8.2

Bolt types and tensile grades

Table 1.14 Figure

Tightening torque

Bolt type

Designation

Tensile grade

M6S

Hexagon screw

8,8 10,9

MC6S

Hexagon hole screw

8,8 10,9 12,9

MF6S

Hexagon hole screw, countersunk

10,9

MCS

Slotted screw

4,6

ATLET SERVICE MANUAL

1.18

General information and technical dataon

Table 1.14 Figure

Bolt type

Designation

Tensile grade

MVBF

Oval head countersunk screw

4,6

Marking with the manufacturer’s trademark, including the tensile grade, is compulsory for screws with a thread diameter from 5 mm and in tensile grades according to the table 1.15 above. Marking only takes place when the shape of the product permits this.

8.8 8.8

12.9 12.9 SM 031.1

Figure 1.7 Example of marking

ATLET SERVICE MANUAL

Tightening torque

General information and technical dataon

1.9

1.19

Lubrication chart 0

1.9.1

Lubrication chart AJN / ASN

A

B K C

K

C L E M F N

O G P

A/B-Service

SM 072.1

Figure 1.8 Lubrication chart AJN / ASN

Table 1.15 Location

Lubrication chart

Explanation

Location

Explanation

A

Mast profile – roller surfaces and slide surfaces

K

Thrust rollers – all

B

Lift chains, all

L

Shaft and Chain pulley

C

Fork carriage – thrust rollers

M

The speed controller’s torsion springs

E

Bogie – axle (unloaded)

N

Hydraulic oil, filter

F

Guide nut / Guide bearing

O

Brake fluid

G

Steering chain top and bottom

P

Gearbox oil

ATLET SERVICE MANUAL

1.20

General information and technical dataon

Important!

All torsion springs in the machine should be lubricated during each service.

For explanation of symbols, see section 1.9.3.

1.9.2

Lubrication chart ATF

A

B K K

C C

L D M E N

F O

H

I

P

A/B-Service Yearly Service SM 073.1E

Figure 1.9 Lubrication chart ATF

Table 1.16 Location

Explanation

Location

Explanation

A

Mast profile – roller surfaces and slide surfaces

I

Steering chains, top, bottom

B

Lift chains, all

K

Thrust rollers – all

C

Fork carriage – thrust rollers

L

Chain pulley, Shaft

D

Forks, rollers, slide surfaces

M

The speed controller’s torsion springs

E

Chains Fork driving

N

Hydraulic oil, filter

F

Guide nut / Guide bearing

O

Brake fluid

H

Angle gear

P

Gearbox

ATLET SERVICE MANUAL

Lubrication chart

General information and technical dataon

1.21

Important!

All torsion springs in the machine should be lubricated during each service.

For explanation of symbols, see section 1.9.3.

1.9.3

Symbol explanations, lubrication chart

Table 1.17 Symbol

Explanation

Symbol

Explanation

Hydraulic oil

Hydraulic oil, change

Gearbox oil

Gearbox oil, change

Brake fluid

Brake fluid, change

Grease

Chain spray

Chain spray / oil

Only cold store version

Applicable in general for the symbols: Unfilled symbol – Check / lubrication Filled symbol – Change

Lubrication chart

ATLET SERVICE MANUAL

1.22

1.10

General information and technical dataon

Recommended oil and grease types 0

Table 1.18 Brand

Gearbox oil As per API grade GL-5

Hydraulic oil As per ISO VG 32, VG 15

Grease, ball bearings

Wormge ar oil (Only ATF)

Brake fluid

Normal / Cold store

Normal (32)

Cold store (15)

BP

BP Energear Hypo.

80 W/90 EP

Bartran SHF-S 32

BP Energol SHF-Lt 15

Energreas e LS-EP 2

BP Energol SGXP 150

BP Super Disc Brake Fluid

Castrol

Hypoy C 80 W/90

Hyspin SHS 32

Hydraulic oil OM 15 Alt: Hyspin AWH 15

Speerol SW2 Alt: AP2

Alpha syn T 220

Mobil

Mobilube HD 85 W/90

DTE 13 M SHS 32

Flowrex 1

Mobilple x 48

GLY goyle 30

Shell

Spirax HD 85 W/90

Tellus oil TX 32

Tellus oil T 15

Alvania Grease 2

Tivela WB

Statoil /Exxon

Gear way G5 80 W/90

SHS 32

J 26

Esso MP Grease

Wormgea r oil 375 S

Texaco

Geartex EPC 80 W/90

Rando oil HDZ 32

Rando oil HDZ 15

Synlube CLP 220

Important!

Do not mix different lubricants – definitely not synthetic oil with mineral oil!

ATLET SERVICE MANUAL

Recommended oil and grease types

General information and technical dataon

1.11

1.23

Colour of the truck in accordance with NCS colour codes 0

Table 1.19 Machine colour

Code

Yellow

NCS 0070-Y20R

Medium grey

NCS 7000

Dark grey

NCS 8000

Colour of the truck in accordance with NCS colour codes

ATLET SERVICE MANUAL

1.24

1.12

General information and technical dataon

Colour codes for Atlet’s wiring diagrams Table 1.20 Code

Cable colour

BE

Beige

BL

Blue

BN

Brown

GN

Green

GR

Grey

OR

Orange

P

Pink

R

Red

SB

Black

VO

Violet

W

White

Y

Yellow

Note!

Two-colour cables are shown with both colour codes separated by a slash. E.g. blue-yellow cable is shown with colour code BL/Y.

ATLET SERVICE MANUAL

Colour codes for Atlet’s wiring diagrams

General information and technical dataon

1.13

1.25

Designations for electrical components First letter Table 1.21 Code

Designation

Designation (Eng)

A

Component or function without its own letter in the list

Component or function without its own letter below

C

Contactor

Connector

D

Diode

Diode

E

Electronic component

Electrical component

F

Fuse

Fuse

I

Indicator

Indicator

L

Lamp

Light

M

Motor

Motor

P

Plug

Plug

R

Relay

Relay

S

Switch

Switch

T

Terminal

Terminal

V

Valve

Valve

W

Audible warning unit

Audible warning unit

Code

Designation

Designation (Eng)

B

Brake

Brake

C

Control system

Control system

E

Emergency function

Emergency function

F

Forward

Forward

H

Unit of time

Hour

K

Key

Key

L

Lowering

Lowering

M

Manouvre

Manouvre

P

Pump

Pump

R

Reverse

Reverse

S

Speed

Speed

Second letter Table 1.22

Example SL = Switch for Lowering function

Designations for electrical components

ATLET SERVICE MANUAL

1.26

1.14

General information and technical dataon

Technical abbreviations Table 1.23 Magnitude

Unit

Designation

Current

Ampere

A

Voltage

Volt

V

Resistance

Ohm

Ω

Output

Watt

W

Torque

Newton metre

Nm

Pressure

Pascal

Pa

Table 1.24 Prefix 1000

kilo

k

1000 000

Mega

M

ATLET SERVICE MANUAL

Technical abbreviations

General information and technical dataon

1.15

1.27

Recommended replacement Hoses should be replaced after 5 years, since they are perishable.

Recommended replacement

ATLET SERVICE MANUAL

1.28

ATLET SERVICE MANUAL

General information and technical dataon

Recommended replacement

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Special tools 2.1 List of tools ................................................................................................................... 2.1

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Special tools

2.1

Edition 2001A

2 Special tools 2.1

List of tools 0

Table 2.1 Designation

Part no.

CURTIS, Hand terminal

006581

See figure 2.1

Wheel puller, drive wheel

001209

See figure 2.2

The Curtis Hand terminal is used for adjustments and trouble shooting on the drive system, see section 10.

D IA

O GN

IC ST

S

T TES AM GR PRO GE AN E CH ALU V LL RO Y SC PLA DIS

O INF RE MO

SM O48.1

Figure 2.1 Hand terminal

SM 083.1

Figure 2.2 Wheel puller SM_A_02_e_2001a.fm

List of tools

ATLET SERVICE MANUAL

2.2

ATLET SERVICE MANUAL

Special tools

List of tools

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Service 3.1 Introduction................................................................................................................... 3.1 3.2 Service inspection list.................................................................................................. 3.2 3.2.1 Chassis ..........................................................................................................................3.2 3.2.2 Mast ..............................................................................................................................3.3 3.2.3 Steering .........................................................................................................................3.4 3.2.4 Brake .............................................................................................................................3.4 3.2.5 Hydraulic system ..........................................................................................................3.5 3.2.6 Electrical system ...........................................................................................................3.6 3.3 Code explanations........................................................................................................ 3.7 3.3.1 Chassis ..........................................................................................................................3.7 3.3.2 Mast ..............................................................................................................................3.7 3.3.3 Drive unit ......................................................................................................................3.8 3.3.4 Steering .........................................................................................................................3.8 3.3.5 Brake unit ......................................................................................................................3.9 3.3.6 Hydraulic system ..........................................................................................................3.9 3.3.7 Electrical system .........................................................................................................3.10

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Service

3.1

Edition 2001A

3 Service 3.1

Introduction 0

Service should be carried out regularly four times a year with normal truck usage, i.e. 1000 operating hours per year. The planned service (A and B service) includes stages such as test driving, function tests, replacing filters, changing the oil, and replacing carbon brushes, etc. Servicing takes place at different intervals depending on how many hours the truck has been in operation. When the truck is working in extreme conditions or in demanding environments, servicing must be planned at shorter intervals.

SM_A_03_e_2001a.fm

Introduction

ATLET SERVICE MANUAL

3.2

3.2

Service

Service inspection list 0

The planned service intervals are implemented as shown in the tables on the following pages. For further information about procedures for inspections, repairs and replacement, refer to the respective sections; see the main list of contents.

3.2.1

Chassis Table 3.1 Chassis

Inspection points

Symptom

Inspection

B Service

A Service

Service code

X

1101

Signs/Decals

None, unreadable

Visual

Chassis/covers

Attachment, damage

Visual, tools

X

X

1102

Overhead guard

Attachment

Visual, tools

X

X

1106

Deformation, cracks, other damage

Visual, tools

Damage, wear

Visual

Noise

Listen, tool

X

Attachment

Visual, tools

X

Battery stop, Battery rollers

Damage, attachment

Visual, tools

X

X

1111

Rubber mats, compartment

Damage

Visual

X

X

1105

Attachment

Visual, tools

X

X

Paint

Appearance

Visual

X

Damage

Visual

X

Panel/Plexiglas

Attachment, damage.

Visual, tools

X

1104

Accessories

None

Visual

X

1112

Load wheel

ATLET SERVICE MANUAL

X

X

X

X

1108

1103

Service inspection list

Service

3.2.2

3.3

Mast Table 3.2 Frame

Inspection points Lift chains

Symptom

Inspection

B Service

A Service

Service code 2102

Chain tensioning

By hand

X

X

Damage, chain bolt

Visual

X

X

Damage, chain bolt mounting

Visual, tools

X

X

Deformation, cracks, other damage

Visual, tools

X

Weld damage

Visual

X

Play

Visual, operating test

X

Angle, deformation

Visual

Attachment, rollers

Visual, tools

X

Weld damage

Visual

X

Wear

Visual

X

X

Thrust rollers

Wear

Visual, tools

X

X

Link system, bar

Locking, damage

Visual, tools

X

X

TF chains

Chain tensioning

Visual

X

X

2031

TF forks

Locking, damage

Visual

X

X

2039

Angle gear

Oil level

Visual, tools

X

X

2039

Leakage

Visual, tools

X

X

Function

Visual, tools

X

X

Stabilisers

Function

Visual

X

X

Stabiliser cylinders

Function

Visual

X

X

Spring assembly, stabiliser cylinders

Lubrication

Visual

X

X

Mast

Fork carriage

Service inspection list

X

2101

X

2104

2103, 2107, 2105

2005

ATLET SERVICE MANUAL

3.4

Service

3.2.3

Steering Table 3.3 Steering

Inspection points

Symptom

Inspection

B Service

A Service

Service code

Steering chains

Chain tension

By hand, tools

X

X

4105

Noise

Listen, lubricate

X

X

Gear

Noise

Listen, lubricate

Steering ties

Play

Visual, tools, lubricate

Servo motor

Attachment

X

4104

X

X

4102

Visual, tools

X

X

7118

Carbon brush wear

Visual, tools

X

X

Flexi wheel

Attachment

Visual, tools

X

X

Steering wheel/ wheel spinner

Damage, wear

Visual, function test, tools

X

X

Damage, attachment

Visual, tools

X

X

Function

By hand

X

X

3.2.4

4101

Brake Table 3.4 Brake

Inspection points

Symptom

Inspection

B Service

A Service

Service code

Braking force

Malfunction

Function test, tools

X

X

5101

Parking brake

Malfunction

Function test, tools

X

X

5102

Brake shoe

Wear

Visual, tools

X

X

5104

Brake cylinders

Leakage

Visual

X

X

5103

Brake link/arm

Function, damage

Visual

X

X

5105

ATLET SERVICE MANUAL

Service inspection list

Service

3.2.5

3.5

Hydraulic system Table 3.5 Hydraulic system

Inspection points

Inspection

B Service

A Service

Service code

Oil level

Visual, filling

X

X

6101

Damage, leakage, contamination

Visual, cleaning

X

X

Filter blocked

Visual, replace

X

6102

Function

Function test, stop watch

X

6017

Damage

Visual, replace

X

X

6001

Leakage

Visual, tools, replace

X

X

Weld damage

Visual, tools, replace

Damage, chain attachments

Visual, tools

X

X

Leakage, damage

Visual, tools

X

X

Attachment

Visual, tools

X

X

Nipples

Leakage

Visual, tools

X

X

6017

Pump motor

Function, noise

Listen, tool

X

X

7115

Cable connections

Visual, tools

Arc over

Visual, tools

X

X

Carbon brush wear

Visual, tools

X

X

Carbon brush springs

Visual

X

X

Commutator

Visual, tools

X

X

Leakage

Visual, tools

X

X

Damage

Visual, tools

Noise

Listen

X

X

Malfunction

Test of lever function

X

X

Leakage

Visual, tools

Hydraulic tank

Cylinders

Hoses

Hydraulic pump

Spool valve

Service inspection list

Symptom

X

6106

X

6109

X

6103

X

ATLET SERVICE MANUAL

3.6

Service

3.2.6

Electrical system Table 3.6 Electrical system

Inspection points

Symptom

Inspection

B Service

A Service

Service code

Malfunction

Visual, tools, replace

X

X

7107

Cable break

Visual, tools

X

X

Contactor plate

Visual, tools

X

X

Charging fault

Tools

X

X

Low acid level

Tools

X

X

Low acid weight

Tools

X

X

Damage

Visual

X

X

Low capacity after charging

Tools, DC voltmeter

Transistor system

Cable break

Visual, tools

X

X

7108

Cabling

Damage, break

Visual, tools

X

X

7104

Horn

Malfunction

Function test

X

X

7014

Speed controller

Attachment

Visual, tools

X

7106

Malfunction

Function test

X

X

Fuses

Blown

Visual, replace

X

X

7103

Battery plug

Malfunction

Function test, tools

X

7102

Power lock, warning light

Malfunction

Visual, tools

X

X

7105

Fork drive motor (only ATF)

Function, noise

Listen, tool

X

X

7031

Cable connections

Visual, tools

X

X

Arc over

Visual

X

X

Carbon brush wear

Visual, tools

X

X

Carbon brush springs

Visual, tools

X

X

Commutator

Visual, tools

X

X

Contactors

Battery

ATLET SERVICE MANUAL

7101

X

Service inspection list

Service

3.3

3.7

Code explanations 0

3.3.1

Chassis Table 3.7 Chassis Code

Designation

Check

Refer to chapter

1013

Battery rollers/ locking

Attachment, locking function.

Cleaning.

1101

Machine nameplate/decals

Attachment; text should correspond with machine type, and symbols and warning decals should be fitted.

Check machine number.

1102

Doors

Attachment

1103

Paint

Peeling of paint

1

1104

Panels/Plexiglas

Attached with screws and clips, as well as bonded parts. Peeling of paint

1

1105

Rubber mats/ edging

Attached with glue or screws.

1106

Overhead guard

Cracks in weld joints, collision damage, tightening of screws.

1108

Load wheel

Vulkollan wheel wear. Dirt.

1108

Load wheel bearing

The operation is frictionless, remove any string, plastic bands etc. that have stuck.

1112

Accessories

User Manual, areometer and battery water bottle

3.3.2

1

4

Mast Table 3.8 Mast Code

Code explanations

Designation

Check

Refer to

2021 (ATF)

Thrust rollers

Attachment, damage, wear.

2031 (ATF)

TF chains

Evenly tensioned, locked, wear.

6

2039

TF forks

Oil level, oil change, leakage, function test.

1, 6

ATLET SERVICE MANUAL

3.8

Service

Table 3.8 Mast Code

Designation

Check

Refer to

2101

Mast

Weld damage, angle deformation.

Check max play, cams, slide lugs, shims, attachment of rollers.

Lubricate sliding surfaces.

1, 6

2102

Lift chains

Equally tensioned, split pin bolts and nuts locked, rust, wear, chain pulley locked. Max tensionsing.

6

2103

Mast rollers

Attachment, damage, wear.

2104

Fork carriage

Cracks, damage, parallelism.

6

2107

Rollers in fork carriage

Washers, wear. Lubrication of roller surfaces.

1

2005

Stabilisers

Attachments, lubrication status, and microswitches.

6 ,8 ,10

3.3.3

Drive unit Table 3.9 Drive unit Code

Designation

Check

Refer to

3101

Oil leakage

Leakage from shafts, joints, plugs or material.

5

3102

Oil level

Oil level. Oil change.

1

3103

Sliding bearing

Noise, lubrication

3105

Drive wheel/nuts

Wear, damage, clean, nuts.

3.3.4

5

Steering

Table 3.10 Steering Code

Designation

Check

4101

Flexi wheel, steering wheel/ wheel spinner

Attachment, rotation

7

4102

Steering shaft joint

Play, lubrication.

7

ATLET SERVICE MANUAL

Refer to

Code explanations

Service

3.9

Table 3.10 Steering Code

Designation

Check

Refer to

4104

Sprocket

Shaft locking, lubrication

4105

Steering chains

Play, lubrication

3.3.5

7

Brake unit

Table 3.11 Brake unit Code

Designation

Check

Refer to

5101

Braking force

Braking distance.

5102

Parking brake

Function, cable connections

5103

Brake cylinders

Visible leakage round connections, rubber flaps

11

5104

Brake shoes

Friction surface > min level 3 mm.

11

5105

Brake link/arm

Movement, damage, lubrication

1

3.3.6

11

Hydraulic system

Table 3.12 Hydraulic system Code

Code explanations

Designation

Check

Refer to

6001

Lift cylinders

Leakage by attachments, weld joints, scrapers, piston rod

9

6017

Lowering

Check lowering speed

8

6101

Oil level in tank

Oil level between min and max Damage, leakage

8

6102

Filter

Replace if necessary

8

6103

Hydraulic valve

Leakage between sections, connections and slide. Levers should be easy to operate.

8

6106

Hoses, pipes

Cracks, wear, damage, leakage

6107

Nipples

Leakage

6109

Hydraulic pump

Leakage between pump and motor, noise

8

ATLET SERVICE MANUAL

3.10

Service

3.3.7

Electrical system

Table 3.13 Electrical system Code

Designation

Check

Refer to

7014

Horn

Function

7017

Microswitch

Function

7031

Fork drive motor

Attachment, carbon brush wear, bearing noise, commutator, cleaning of carbon brush dust.

10

7101

Battery

Acid level, charging. Note read-off from hydrometer, clean if necessary.

10

7102

Battery connections

That cable connections are not overheating; cable break.

7103

Fuses

That they are not brittle.

7104

Cabling

Cable connections, attachment, run free from sharp edges, crimp.

7105

Power lock/ warning light

Function, lights up

7106

Speed controller

Attachment and function.

7107

Contactors

Contact surfaces, cable connections, dust guard.

7108

Transistor system

Dirt, moisture. Cable connections, safety test, see?

7112

Drive motor cables

Attachment, damage. Cleaning.

7113

Drive motor Carbon brushes/ bearing

Attachment, carbon brush wear, bearing noise, commutator, cleaning of carbon brush dust.

5

7115

Lift motor Carbon brushes/bearing

Attachment, carbon brush wear, bearing noise, commutator, cleaning of carbon brush dust.

5

7118

Servo motor

Attachment, carbon brush wear, bearing noise, commutator, cleaning of carbon brush dust.

7

ATLET SERVICE MANUAL

10

10

Code explanations

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Chassis 4.1 Introduction................................................................................................................... 4.1 4.2 Tightening torque ......................................................................................................... 4.2 4.3 Caster wheel ................................................................................................................. 4.4 4.3.1 Dismantling ...................................................................................................................4.4 4.3.2 Assembly ......................................................................................................................4.4 4.3.3 Dismantling ...................................................................................................................4.4 4.3.4 Assembly ......................................................................................................................4.5 4.3.5 Adjusting the angle of the truck ....................................................................................4.5 4.4 Panels ............................................................................................................................ 4.6 4.5 Replacing the battery rollers ....................................................................................... 4.7 4.6 Replacing the load wheel, bogie wheel ...................................................................... 4.8 4.6.1 Dismantling ...................................................................................................................4.8 4.6.2 Assembly ......................................................................................................................4.8 4.7 Replacing the load wheel, single wheel ..................................................................... 4.9 4.7.1 Dismantling ...................................................................................................................4.9 4.7.2 Assembly ......................................................................................................................4.9

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Chassis

4.1

Edition 2001A

4 Chassis 00000000

4.1

Introduction 0

The chassis on A-86 trucks consists of a machine housing, which is available in two versions depending on the battery size: Junior and Senior. The mast is attached to the machine housing with a bolt union, the tightening torque of which must be taken into consideration. The drive unit is one of Atlet’s own proven designs, and is to be found on several of Atlet’s different trucks.

SM_A_04_e_2001a.fm

Introduction

ATLET SERVICE MANUAL

4.2

4.2

Chassis

Tightening torque • Tightening torque of the mast system to the machine housing: 120 Nm. See pos. 37, figure 4.3.

• The caster wheel’s tightening torque to the machine housing, pos. 34 figure 4.1: 80 Nm. • The overhead guard is also bolted to the machine housing, and the tightening torque for the bolts, pos. 22 and 23 figure 4.1, should be: 35 Nm. See table in section 1.

1

72

15

16

14 13 19 17 12

25 26

18 22

30 28

11 13

10

29

18

8

31

27

24 23

9

7

20 3

21

32

6 56

4

57 58

5

33

34

2

35 68

73 70

36 39

71

71

69

59

40

37

41

60

42

38

43 61

44 62

63

45

64 46 65

47

51

48 49

66 50

53 67

A 72.1

54

52 55

Bild 4.1 Chassies

ATLET SERVICE MANUAL

Tightening torque

Chassis

4.3

41 42 43 44 45 46 47

51

48 49 50 53

54

52

55

pA 72.1

Bild 4.2 Swivel wheel

37 pC 52.2

Bild 4.3 Mast example

Tightening torque

ATLET SERVICE MANUAL

4.4

4.3

Chassis

Caster wheel The caster wheel is a completely separate and free-turning wheel placed under the driver. It consists of a double-wheel mounted in a wheel fork. Between and at the sides of the wheel there are spacer washers, which have the purpose of guiding the wheel to the correct position in the wheel fork.

Shims are mounted between the caster wheel’s attachment plate and the machine housing to compensate for differences in the diameter of the drive wheel. See pos.

39, figure 4.1.

Note!

When the drive wheel becomes worn, compensate with shims to counteract the entire truck leaning sideways, or the drive wheel spinning. Check the number of shims when replacing the drive wheel.

4.3.1

Dismantling

1

Check that the battery is pushed in and locked.

2.

Place a jack under the centre of the truck’s rear end.

3.

Lift up the truck a few centimetres, and check the balance.

4.

Loosen the bolts to the caster wheel, and remove them.

Warning!

Pinch risk!

5.

Carefully lift up the truck so that the caster wheel and fork can be pulled forward. Secure the truck with blocks.

4.3.2

Assembly

1

Move the caster wheel in under the truck.

2.

Lift up the caster wheel and place the shims in position.

3.

Insert the bolts and tighten.

4.

Remove the blocks and lower down the truck.

5.

Check the angle of the truck.

4.3.3

Dismantling

1

Support the complete caster wheel in a vice by gripping the opposite side of the wheel fork where the retaining pin is fitted.

2.

Tap out the retaining pin, pos. 45 figure 4.2, and drive out the shaft, pos. 51.

3.

Lift out the caster wheel from the wheel fork; take care of the spacers.

ATLET SERVICE MANUAL

Caster wheel

Chassis

4.

4.5

Dismantle the bearings from the caster wheel by means of a bearing extractor.

4.3.4

Assembly

1

Press the bearings in the caster wheel with a drift.

2.

The shaft is lubricated with oil before fitting.

3.

Insert the caster wheel with the shims in the wheel fork.

4.

Check that the hole for the retaining pin in the shaft comes opposite the hole on the wheel fork.

5.

Carefully press in the shaft be using a hammer and a suitable drift.

6.

Fit the retaining pin.

7.

Turn the caster wheel and check that it rotates freely.

8.

Fit the caster wheel in the machine.

4.3.5

Adjusting the angle of the truck

The angle of the truck can be adjusted by shimming the caster wheel.

• Place the truck on a level surface.

• Check the angle of the truck by holding a spirit level to the sides of the mast and checking the angle of the mast. Alternatively, check with a measuring scale on both sides of the truck between the machine housing and the floor.

• If the truck needs aligning, this can be done by shimming the caster wheel.

Dismantle the caster wheel as shown in section 4.2.1 and add or remove shims, pos. 39 figure 4.1. Fit the caster wheel, and check.

• Shims are available in several different dimensions.

Caster wheel

ATLET SERVICE MANUAL

4.6

4.4

Chassis

Panels 0

The recyclable panels are manufactured of durable, vacuum-shaped ABS plastic.

ATLET SERVICE MANUAL

Panels

Chassis

4.5

4.7

Replacing the battery rollers 0

1

Remove the battery.

Warning!

Observe care to avoid “splashing” waste acid or oxide from the battery in your eyes.

2.

The battery rollers are best replaced by tapping the retaining pin down with a small drift and then lifting up the shaft with the rollers.

Replacing the battery rollers

ATLET SERVICE MANUAL

4.8

4.6

Chassis

Replacing the load wheel, bogie wheel 0

4.6.1

Dismantling

1

Lift up the forks and tap out the retaining pin, pos. 23 figure 4.4.

2.

Use a jack to lift up the support arm enough for the bogie to be lifted off the floor, and secure with blocks.

3.

Tap out the shaft, pos. 24, and lift out the bogie.

4.

Remove the retaining pins, pos. 28, and drive out the shafts, pos. 26, and lift out the wheel, spacer washer and seals from the bogie fork.

5.

If the wheel bearings are not to be replaced, use a bearing extractor and carefully pull out the bearings.

23 1

27 24

25

30 26

28 29 32 31

PC 86.1 33

Bild 4.4 Bogie wheel

4.6.2

Assembly

1

Press the bearings in the wheel.

2.

Check that the shafts, holes in the bogie fork and the support arm fork are not damaged. Replace or repair anything that is damaged.

3.

Lubricate the shafts, bearings and holes for the shafts with oil or a thinbodied rust inhibitor.

4.

Fit the parts, not forgetting the spacers. When the shafts are pressed in place, check that the hole for the retaining pin in the shafts is in line with hole in the bogie fork and support arm.

5.

Fit the retaining pins, lower down the truck and test drive.

ATLET SERVICE MANUAL

Replacing the load wheel, bogie wheel

Chassis

4.7

4.9

Replacing the load wheel, single wheel 0

4.7.1

Dismantling

1

Lift up the forks and tap out the retaining pin, pos. 23 figure 4.5.

2.

Use a jack to lift up the support arm enough for the wheel to be lifted off the floor, and secure with blocks.

3.

Tap out the shaft, pos. 24; take care of the spacers between the wheel and support arm fork, and lift out the wheel.

4.

If the wheel bearings are not to be replaced, use a bearing extractor and carefully pull out the bearings.

23

24

p2C 86.1

34 35

36

Bild 4.5 Singel wheel

4.7.2

Assembly

1

Press the bearings in the wheel.

2.

Check that the shaft and holes in support arm fork are not damaged. Replace or repair anything that is damaged.

3.

Lubricate the shaft, bearings and holes in the support arms with oil or a thinbodied rust inhibitor.

4.

Fit the parts, not forgetting the spacers. When the shaft is pressed in place, check that the hole for the retaining pin in the shaft is in line with hole in the support arm.

5.

Fit the retaining pin, lower down the truck and test drive.

Replacing the load wheel, single wheel

ATLET SERVICE MANUAL

4.10

ATLET SERVICE MANUAL

Chassis

Replacing the load wheel, single wheel

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Drive unit 5.1 Introduction................................................................................................................... 5.1 5.2 Dismantling and assembling the drive unit ............................................................... 5.2 5.3 Drive motor ................................................................................................................... 5.5 5.3.1 Storage ..........................................................................................................................5.5 5.3.2 First service ...................................................................................................................5.5 5.3.3 Preventive maintenance ................................................................................................5.5 5.4 Reconditioning the motor............................................................................................ 5.6 5.4.1 Brush holders ................................................................................................................5.6 5.4.2 Motor bearings ..............................................................................................................5.6 5.4.3 Commutator and replacing the carbon brushes .............................................................5.6 5.4.4 Reasons for burned motors ...........................................................................................5.8 5.4.5 Stator housing ...............................................................................................................5.8 5.4.6 Assembly ......................................................................................................................5.9 5.5 Insulation test ............................................................................................................. 5.10 5.6 Gearbox ....................................................................................................................... 5.11 5.6.1 First service .................................................................................................................5.11 5.6.2 Preventive maintenance ..............................................................................................5.11 5.7 Trouble shooting chart .............................................................................................. 5.12

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Drive unit

5.1

Edition 2001A

5 Drive unit 00000000

5.1

Introduction The drive unit, with the exception of the motor, is Atlet’s own design and is to be found on the X-90, A, AP and L series trucks. There are differences in the gear ratios, with hardened or unhardened gear sets.

SM_A_05_e_2001a.fm

Introduction

ATLET SERVICE MANUAL

5.2

5.2

Drive unit

Dismantling and assembling the drive unit • Remove the rear, lower cover.

• Remove the drive wheel nut, pos. 14 figure 5.1, with a 32 mm box spanner.

Tightening torque 300 Nm when refitting.

• Lift the truck on the left side so that the drive wheel comes free from the floor, and secure with blocks. Release the drive wheel with a wheel puller.

• Dismantle the complete brake disk, pos. 12, by loosening its bolts, pos. 36, moving it to one side and then lifting off the drive wheel.

• Remove the drive motor cables from the drive motor, replace the complete brake disk, turn the drive unit 180°, and loosen the three bolts, pos. 4, holding the drive motor.

• Turn the drive unit back 180° and release the complete brake disk, lift out the drive motor, pos. 10, and fit the complete brake disk loosely.

2 3

1 4 5

6

11

7

36 8

9

10 pB 49.2

13

14

12 8

Figure 5.1 Drive unit • Drain off the oil in the drive unit by unscrewing the filler plug, pos. 1, and the drain plug, pos. 24 figure 5.2. Remove the cover, pos. 5, by unscrewing the screws, pos. 3 figure 5.2.

• Use two of the screws in the threaded holes to pull off the cover. Carefully tap the cover at the same time with a hammer.

Important!

Observe care, otherwise the cover can crack.

• Remove the wear washer, pos. 8 figure 5.2. Take care of the needle bearing, pos. 9, 17 (the outer part can drop on the floor), and take off the gear, pos. 14.

ATLET SERVICE MANUAL

Dismantling and assembling the drive unit

Drive unit

5.3

• Loosen and remove the lock nut, pos. 6, with the intended box spanner.

Tightening torque 100 Nm when refitting. Fit two M10 bolts in the lower gear, pos. 15, and pull off the gear. Take care of the shims, pos. 26. When fitting, shim so that the clearance between the ball bearing, pos. 27, and the shoulder is max 0.4 mm and min 0.1 mm.

• Turn the drive unit 180°, remove the cover, pos. 34, by unscrewing the screws, pos. 36, turn the drive unit 180°, and tap out the drive shaft, pos. 31, with a rubber mallet or copper hammer.

• Pull off the bearing, pos. 29, from the drive shaft with a suitable extraction tool, and drive out the retaining pin, pos. 20, and shaft, pos. 18, with a drift.

• Loosen the nut, pos. 10, for the motor gear, and pull off the gear with a suitable extraction tool.

Important!

Before fitting make sure that all parts are carefully cleaned, and lubricate seals, rings, shafts and bearings with gearbox oil.

Assemble in the reverse order.

The tightening torque for the nut to the motor gear, pos. 10, is 35 Nm.

Dismantling and assembling the drive unit

ATLET SERVICE MANUAL

5.4

Drive unit

1 2

10 3

11

4

12 7

8

13

9

16

17 18

5

8 7

6 14 15 19 20

25 24

22 23

30 26 27 29

35 36

31 32

K

33 34

27 28 29 26

B 38.3

Figure 5.2 Gearbox

ATLET SERVICE MANUAL

Dismantling and assembling the drive unit

Drive unit

5.3

5.5

Drive motor 0

For further technical information regarding the drive motor, see section 1 “Technical data”.

Warning!

The battery plug must be removed and the machine lifted so that the drive wheel runs free of the ground when working on the motor.

5.3.1

Storage

Machines in storage that will not to be used within a month, must be given special attention so that problems do not occur when they are to be used again. Dust, dirt, condensation and moisture that occurs during large changes in temperature, as well as problems with rust and oxidisation must be prevented. Consequently motors should be protected using waxed paper or the like, as well as using a moisture absorbing material, e.g. silicon gel.

5.3.2 1 2.

3.

First service

Check that no noise comes from the motor bearings.

Check that the commutator does not have an abnormal colour. It should have a fine, grey surface (patina).

Check that there are no abnormal vibrations while running.

5.3.3

Preventive maintenance

Preventive maintenance is implemented in accordance with the intervals set out in the service chart. See section 3, “Service”. However, in some cases exceptions must be made and the intervals can be shortened, depending on the conditions in customer’s premises, e.g. a rugged environment with dust, high humidity levels, salt, etc.

1

Check carbon brush wear. Minimum permitted length as shown in the table 5.1.

Note!

An assessment must be made from case to case concerning the length of the carbon brushes, and if they are sufficiently long to wait for the next service.

2. Check that the carbon brushes move easily in the holders, and that the connections are tightened.

3. Check that the stator poles are secure, and that they are free from dirt, carbon dust and moisture. Measure the resistance between the coil and stator housing; it should not be less than 24 kOhm. 4. Listen for noise from the bearings when the motor is run. Check that it does not vibrate abnormally.

5. Blow clean the motor with dry compressed air, or use a vacuum cleaner. A mild soap detergent should be used to drive out oil and dirt, if oil has leaked from the gearbox into the motor. Finally, blow dry with compressed air.

Drive motor

ATLET SERVICE MANUAL

5.6

5.4

Drive unit

Reconditioning the motor 0

A total overhaul of the motor is recommended after 2000 hours of operation, or after every third replacement of the brushes. The motor should be removed from the drive unit, see section 5.2 and 5.3. After this dismantle the motor so that the end shields, armature and carbon brush holders are released. The field in the stator housing should not be removed.

5.4.1

Brush holders

Check the brush springs. If any of them have burned or lost their elasticity, all the brush springs should be replaced. If a brush holder is burned, this should also be replaced.

5.4.2

Motor bearings

Motor bearings are always replaced when renovating the motor, or after max 5000 hours of operation or alternatively 5 years, to guarantee its reliability. The bearings are of Z/C3 type and are lubricated with Chevron SR12. If the bearings are lubricated between these intervals it is important to only fill them to half, to avoid overheating.

5.4.3

Commutator and replacing the carbon brushes

The armature is cleaned from dust and dirt. The commutators running surface should be greyish-black and smooth. It must not be worn, fluted or deformed. The segments must not be displaced, which can cause bits to be broken loose from the edges of the carbon brushes. Worn or fluted commutators should be faced during every basic overhaul.

Important!

Commutators must not be treated with emery cloth or files.

A commutator cannot be turned down an arbitrary number of times. A specific minimum diameter must be maintained. The following is applicable: A rotor where the commutator is turned often with a conservative loss of material will last longer than a commutator turned fewer times with a significant loss of material. For this reason turn the commutator at the correct interval, or no later than every 3rd time the brushes are replaced.

Note!

Treating the commutator with sandstone for rapid trimming of the carbon brushes is not recommended for this motor. After changing the brushes the motor must not be loaded at full power immediately. At low loads the carbon brushes wear in relatively quickly and therefore do not require special grinding procedures.

ATLET SERVICE MANUAL

Reconditioning the motor

Drive unit

5.7

Table 5.1 Data carbon brush length/collector diameter

Dimension

Carbon brush length, new brush

30.5 mm

Worn length

15.5 mm

Consumed with a length of

15.0 mm

Cummutator diameter, new

60.0 mm

The commutator should be replaced at a diameter of

57.5 mm

Data for turning: Table 5.2 Data for turning: Cutting speed with hard metal

Min 200m/sec

Feeding

Max 0.05 mm/revolution

Cutting depth

Max 0.05 mm

Distortion during indication in lathe

Max 0.02 mm

Table 5.3 Re-turning Ovality, fixed dimension from bearing points

Max 0.03 mm

Permitted diameter of commutator

See table 5.2 above.

Segment displacement

Max 0.02 mm

Keyway slotting depth

0.6 mm (See figure 5.3)

Segment breaking

0.2 mm (See figure 5.3)

The carbon brushes can be considered to be worn in when the running surface amounts to approx. 40%.

Reconditioning the motor

ATLET SERVICE MANUAL

5.8

Drive unit

SM O57.1

Figure 5.3 Keyway slotting depht and segment breaking

5.4.4

Reasons for burned motors

The terminal voltage level of a battery when loaded not only depends on the current, capacity, design and temperature. It depends on the battery’s charging state, since the more a battery is discharged, the more the voltage drops when loaded.

Consequently the motor speed also drops, which results in poorer cooling and the risk of overloading. In the final phase of battery discharging the voltage drops more quickly, so that the motor can no longer provide the requisite torque and stops, i.e. comes into a short-circuit state.

Motors that have burned when idle can be recognised by the burn damage the brushes have caused on the commutator. For this reason it is extremely important that batteries are immediately recharged if a significant drop in the engine speed is noticed.

The following should be taken into consideration for preventive reasons: • Excessive rolling resistance to the floor or pallet pushing eliminated.

• Repeated driving on extremely long ramps requires extra cooling.

• Discharged batteries charged immediately.

5.4.5 1 2.

3.

4.

Stator housing

Flush the stator housing with a mild alkaline detergent, and blow dry.

Check that the carbon brushes move easily in their respective holders, and also that the brush springs are flexible and have not been attacked by rust.

Check that the cable connections are correctly tightened.

Check that the insulation is satisfactory. This should not be more than 24 kOhm. If the resistance is lower the motor must be blown clean and tested again.

ATLET SERVICE MANUAL

Reconditioning the motor

Drive unit

5.4.6

5.9

Assembly

Assemble in the reverse order. Finally, check that the connections from the field to the carbon brush holders are correctly connected and tightened.

Reconditioning the motor

ATLET SERVICE MANUAL

5.10

5.5

Drive unit

Insulation test

Note!

The test instrument should comply with the following EU standards: EN 1175 §5.15.1, §5.15.2, §5.15.3 Test instruments can be ordered from Atlet Parts: P/N 11111

Warning!

The instrument has a dangerous voltage over the measuring terminals, therefore only test machines, not persons!

Routines for insulation testing of all truck models.

1 2.

3.

4.

5.

6.

7.

8.

Take out the insulation measurement instrument.

Set the test voltage to 100 volt.

Separate the truck’s battery plugs from each other. Certain electrical components and electronic systems can be damaged by the test voltage.

For this reason disconnect connections to these before doing the test.

Connect the instrument’s earth lead to the truck chassis at a point with good electrical contact. The other lead is connected to the electrical panel plug’s positive terminal.

Press the start button and wait until the display has stabilised, then release the button and read-off the value on the display.

An approved value on 24 volt machines should be at least 24000 ohm, (24 kohm).

An approved value on 48 volt machines should be at least 48000 ohm, (48 kohm).

Let the earth lead remain attached to the chassis and connect the other lead to the electrical panel plug’s negative terminal. After this repeat point 5.

Insulation test of a newly charged battery mounted in the truck: Leave the earth lead in the chassis and connect the other lead to the battery plug’s positive terminal. Press the start button and wait until the display has stabilised, then release the button and read-off the value on the display.

An approved value on 24 volt machines should be at least 1200 ohm, (1.2 kohm).

An approved value on 48 volt machines should be at least 2400 ohm, (2.4 kohm).

Repeat point 7, but now measure on the battery plug’s minus terminal instead.

Important!

Unapproved values imply that the truck must be repaired.

ATLET SERVICE MANUAL

Insulation test

Drive unit

5.6

5.11

Gearbox 0

For further technical information regarding the gearbox, see section 1 “Technical data”.

5.6.1

First service

The first oil change should be made after 250 hours of operation.

1 2.

Drain the oil from the gearbox.

Fill with oil. Recommended type of oil, see section 1 “General information”.

5.6.2

Preventive maintenance

The oil should be changed after approximately 2000 hours of operation, or at least once a year.

Note!

Do not forget to fill the gearbox with oil before starting up. The oil can be filled before the drive motor is mounted on the gearbox. First check that the oil level is correct: open the level plug and drain off excess oil.

Note!

Spent oil should be taken care of and recycled according to the applicable legislation in respective countries.

Gearbox

ATLET SERVICE MANUAL

5.12

5.7

Drive unit

Trouble shooting chart Table 5.4 Symptom

Cause

Action

The wheel has a flapping noise.

The tyre has separated.

Change the wheel and check the floor for bumps.

The wheel squeaks, rattles or grates when driving.

Bearing is damaged.

Replace the bearing and inform the driver that cords and plastic etc. should be removed daily and the floor kept clean.

The wheel has a deformation that does not disappear when driving.

Locking of the brakes so that the wheel slides, or loose objects on the floor that prevent the wheel from rotating.

Remove objects from the floor and inform the driver that he/she should brake more smoothly.

The wheel has transverse cracks, and small bits have fallen out of the tyre.

The wheel has been heated.

Small cracks appear with hard acceleration and reversing.

Adjust down the acceleration and reversing rate, and change the wheel if necessary.

The wheel has one or more small deformations.

Locking of the brakes so that the wheel slides, or loose objects on the floor that prevent the wheel from rotating.

Remove objects from the floor and inform the driver that he/she should brake more smoothly.

ATLET SERVICE MANUAL

Trouble shooting chart

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Mast 6.1 Introduction................................................................................................................... 6.1 6.2 Dismantling and assembling the masts, general ...................................................... 6.2 6.2.1 Assembling, dismantling to: A -15000 .........................................................................6.2 6.2.2 Assembling, dismantling from: A -15000 ....................................................................6.2 6.3 Mast system to: A -15000............................................................................................. 6.3 6.3.3 Adjusting the brass lugs ................................................................................................6.3 6.3.4 Adjusting the mast top ..................................................................................................6.3 6.3.5 Dismantling the DTFV mast .........................................................................................6.4 6.3.6 Dismantling the TFV mast ............................................................................................6.6 6.3.7 Dismantling the TV mast ..............................................................................................6.8 6.3.8 Dismantling the DT mast ............................................................................................6.10 6.3.9 Dismantling the T mast ...............................................................................................6.12 6.4 Mast system from: A -15000 ...................................................................................... 6.14 6.4.1 Dismantling the DTFV mast .......................................................................................6.14 6.4.2 Dismantling the TFV mast ..........................................................................................6.15 6.4.3 Dismantling the TV mast ............................................................................................6.18 6.4.4 Dismantling the T mast ...............................................................................................6.20 6.5 Fork carriage............................................................................................................... 6.22 6.5.1 Adjusting to: A -15000 ...............................................................................................6.22 6.5.2 Adjusting from: A -15000 ...........................................................................................6.22 6.5.3 Dismantling .................................................................................................................6.23 6.5.4 Dismantling the fork carriage ATF .............................................................................6.24 6.5.5 Assembling the fork carriage ATF .............................................................................6.26 6.5.6 Checking the fork carriage ATF truck ........................................................................6.26 6.5.7 Overload clutch ...........................................................................................................6.26

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

6.6 Forks............................................................................................................................ 6.28 6.6.1 Adjusting forged forks ................................................................................................ 6.28 6.6.2 Adjusting welded forks ............................................................................................... 6.28 6.6.3 Fork test ...................................................................................................................... 6.29 6.7 Checking the lift chains ............................................................................................. 6.31 6.7.1 Regular maintenance .................................................................................................. 6.32 6.7.2 Re-fitting the chains .................................................................................................... 6.32 6.8 Straddle lift.................................................................................................................. 6.33 6.8.1 Adjusting .................................................................................................................... 6.33 6.8.2 Dismantling and assembling, T, TF, DT, DTF ........................................................... 6.33 6.8.3 Dismantling and adjusting, TV, TFV, DTFV ............................................................. 6.35 6.9 Side stabilisers ........................................................................................................... 6.37 6.9.1 Dismantling and assembling ....................................................................................... 6.37 6.9.2 Assembling ................................................................................................................. 6.39 6.9.3 Checking the side stabiliser ........................................................................................ 6.40 6.9.4 Adjusting the side stabilisers ...................................................................................... 6.41 6.10 Lift cylinders ............................................................................................................. 6.42 6.10.1 Adjusting the cylinder attachment in the mast ......................................................... 6.42 6.10.2 Adjusting the cylinder attachment in the mast from A - 15000 ............................... 6.43

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Mast

6.1

Edition 2001A

6 Mast 00000000

6.1

Introduction 0

There are five mast systems as standard versions, depending on the application or roof height, etc.

Table 6.1 Designation

Description

T

Telescopic mast

DT

Double Telescopic mast

TV

Telescopic Free-view mast

TFV

Telescopic Free-lift Free-view mast

DTFV

Double Telescopic Free-lift Free-view mast

A telescopic mast consists of an outer and inner mast, fork carriage and lift cylinder.

The fork carriage is lifted up and down in the inner mast, which in turn moves up and down in the outer mast. The lift cylinder first lifts the fork carriage approx.

15 cm, and then the mast system follows the lifting movement.

A mast of the double telescopic type also has, in addition to an inner and outer mast, an intermediate mast. The lifting movement is the same as for a telescopic mast, and all the masts begin to move up (or down) simultaneously.

A mast type with free-lift function works in a similar way, but with the difference that the fork carriage moves to its top position in the inner mast before the next mast section starts to lift. Free-lift masts can be used to advantage in rooms with low ceilings or low door openings.

A mast of the free-view type implies that the distance between the mast profiles is wider, which gives better visibility.

SM_A_06_e_2001a.fm

Introduction

ATLET SERVICE MANUAL

6.2

6.2

Mast

Dismantling and assembling the masts, general The following is generally applicable for all types of masts when dismantling: • Stand in an area with adequate ceiling height and with approved lifting devices.

The following is generally applicable for all types of masts when assembling: • The mast is assembled in the reverse order to dismantling.

6.2.1

Assembling, dismantling to: A -15000 Table 6.2 Maximum free play to: A -15000

mm

Fork carriage

Lower/outer side thrust rollers and roller surfaces, mast

3,0

Fork carriage

Upper/inner side thrust rollers and roller surfaces, mast

1,0

Mast

Side thrust rollers and roller surfaces

1,0

• The screws on the shaft journal washers are fitted with Loctite, heat them if necessary. Observe local safety regulations. When replacing the thrust rollers, the roller’s inner ring should also be replaced.

6.2.2

Assembling, dismantling from: A -15000 Table 6.3

Mast

ATLET SERVICE MANUAL

Maximum free play from: A -15001

mm

Thrust rollers and roller surfaces between mast sections

1,0

Dismantling and assembling the masts, general

Mast

6.3

6.3

Mast system to: A -15000 6.3.3

Adjusting the brass lugs

Make sure the maximum play by the brass lugs on the mast’s lower section, figure 6.1 pos. 42, does not exceed 0.4 mm. The play between thrust roller and mast is measured with feeler gauges. The play is adjusted by inserting the requisite number of shims, pos. 43.

42 43

44 45 46

pC 200.3

Figure 6.1 Mast foot

6.3.4

Adjusting the mast top

1

The four brass screws, pos. 32, in the top of the outer mast and intermediate mast, are tightened until they contact. After which they are released 90°.

Secure with lock nut, pos. 31.

2.

The four cams, pos. 4, in the top of the outer mast and intermediate mast, should be adjusted until they are in contact with the roller surface. The mast sections should be parallel.

1 2

3 4 5 6

30

31 32

p2C 200.3

Figure 6.2 Mast top

Important!

After the requisite adjusting, repeat the lifting movements and check that the mast system does not jam anywhere. All the sliding surfaces must be regularly lubricated.

Mast system to: A -15000

ATLET SERVICE MANUAL

6.4

Mast

6.3.5

Dismantling the DTFV mast

1

Lift the forks approx. 1 m and unscrew the stop bolt in the inner mast channel’s lower section, pos. 68 figure 6.3.

2.

Remove the shims and slide lugs, pos. 57, 58 on both sides.

3.

Release side thrust roller cams, pos. 8, and the four adjusting bolts, pos. 11.

4.

Run the support arm into a pallet, put another pallet on the other, and lower the fork carriage down on to them until the chains go slack.

5.

Remove the pin that fastens the chain at the fork carriage’s chain bolt, and lift until the fork carriage comes free from the inner mast.

6.

Reverse the truck to the area for dismantling the mast.

7.

Place a wooden block on the support arm between the outer mast profiles, and remove the upper retaining screws for the side cylinders on both sides.

Lower so that the inner mast rests on the wooden block.

8.

Remove the two outer chains by releasing the chain bolts on the inner mast’s lower strut, and remove the pins on both sides that fasten the chain at the chain bolt. After this remove the pins that fasten the chains at the outer mast’s upper strut.

9.

Release the hoses that run in the mast at the lower distribution block, and plug them.

10. Attach a lifting device on the inner mast’s upper strut, lift the inner mast half way, and remove the lifting stop.

11. Tie a rope round the inner mast’s lower strut and hitch it round the front part of the overhead guard (between the flat bars).

12. Lift the inner mast until its lower rollers, pos. 4, meet the intermediate mast’s rollers, pos. 4. Stretch the rope round the lower strut and run the overhead crane in the lengthwise direction of the support arm from the machine, while lowering the inner mast’s upper section at the same and stretching the rope round the lower strut.

13. When the inner mast is horizontal in relation to the outer mast, it can be lifted out by stretching the rope round the lower strut.

14. Lift in the upper strut and carefully release the rope in the lower strut to counteract the pendulum movement that occurs.

15. Secure the side cylinders so that they cannot drop out.

16. Lift out the intermediate mast in the same way as the inner mast.

ATLET SERVICE MANUAL

Mast system to: A -15000

Mast

5

6.5

6 7 8 9

44

10 45

43 40

41

42

41

40

46

48

22

19

22

20 13 12

56

14

20 21 49 50 51

55

21

11

19

3

4

15 16

2

10

17

9 8

18

53

6

5

47

52 57

13

39

50

58

7

12

11

68 1

59 60

38 37

61 65 66

8

7

6

10 28 2

3

4

5

9 23

27 29

24

25

26 62

30 31

32

63

33

64

23 23

1

27 24

28

24

C 63.4

34

35

36

25

30 26

31

29 32

33

Figure 6.3 DTFV to: A-15000

Mast system to: A -15000

ATLET SERVICE MANUAL

6.6

Mast

6.3.6

Dismantling the TFV mast

1

Lift the forks approx. 1 m and unscrew the stop bolt in the inner mast channel’s lower section, pos. 51 figure 6.4.

2.

Remove the shims and slide lugs, pos. 36 and 37, on both sides.

3.

Run the support arm into a pallet, put another pallet on the other, and lower the fork carriage down on to them until the chains go slack.

4.

Remove the pin that fastens the chain at the intermediate cylinder’s chain bolt, and place the chain on the fork carriage.

5.

Lift until the fork carriage comes free, and reverse the truck out of the way.

6.

Place a wooden block on the support arm between the outer mast profiles, and release the bolts that fasten the outer cylinders at the outer mast’s upper strut.

7.

Secure the outer cylinders so that they cannot drop out.

8.

Lower until the inner mast rests on the wooden block and the hydraulic system become pressureless. Press the piston rods down by hand the last bit if necessary.

9.

Release the hydraulic connection to the intermediate cylinder’s pressure hoses at the junction between the mast and chassis, and plug them.

10. Release side thrust roller cams, pos. 8, and the adjusting bolts, pos. 11.

11. Attach a lifting device on the inner mast’s upper strut, lift the inner mast half way, and remove the lifting stop.

12. Tie a rope round the inner mast’s lower strut and hitch it round the front part of the overhead guard (between the flat bars).

13. Lift the inner mast until its lower rollers, pos. 4, meet the outer mast’s rollers, pos. 4. Stretch the rope round the lower strut and run the overhead crane in the lengthwise direction of the support arm from the machine, while lowering the inner mast’s upper section at the same and stretching the rope round the lower strut.

14. When the inner mast is horizontal in relation to the outer mast, it can be lifted out by stretching the rope round the lower strut.

15. Lift in the upper strut and carefully release the rope in the lower strut to counteract the pendulum movement that occurs.

ATLET SERVICE MANUAL

Mast system to: A -15000

Mast

6.7

14 15 16 17 18 35

10 9 8

41

3

4

42

2

7

6

5

44

43

45 13

36

12

11

37 1

51

38 39

34 33

40 10 4 2

9

3

8

49 50

7

6

5

24 19

23 25 20 21 26

27

28

22 46

29

47

48 19

19

1

23 20 20

C 87.1

30 31

32

21

26 22

24 25 28 27 29

Figure 6.4 TFV to: A-15000

Mast system to: A -15000

ATLET SERVICE MANUAL

6.8

Mast

6.3.7

Dismantling the TV mast

1

Lift the forks approx. 1 m and unscrew the stop bolt in the inner mast channel’s lower section, pos. 52 figure 6.5.

2.

Remove the shims and slide lugs, pos. 44 and 45.

3.

Run the support arm into a pallet, put another pallet on the other, and lower the fork carriage down on to them until the chains go slack.

4.

Remove the pin that fastens the chain at the outer mast’s upper section on both sides, and place the chains on the fork carriage.

5.

Lift until the fork carriage comes free from the inner mast.

6.

Reverse the truck to the area for dismantling the mast.

7.

Place a wooden block on the support arm between the outer mast profiles, and release the bolts that hold the piston rods for the lift cylinders in the inner mast.

8.

Secure the cylinders so that they cannot drop out.

9.

Lower until the hydraulic system becomes pressureless, and push down the piston rods the last bit by hand if necessary.

10. Release the side thrust roller cams, pos. 8, and the adjusting bolts, pos. 11.

11. Attach a lifting device on the inner mast’s upper strut, lift the inner mast half way, and remove the lifting stop.

12. Tie a rope round the inner mast’s lower strut and hitch it round the front part of the overhead guard (between the flat bars).

13. Lift the inner mast until its lower rollers, pos. 4, meet the outer mast’s rollers, pos. 4. Stretch the rope round the lower strut and run the overhead crane in the lengthwise direction of the support arm from the machine, while lowering the inner mast’s upper section at the same and stretching the rope round the lower strut.

14. When the inner mast is horizontal in relation to the outer mast, it can be lifted out by stretching the rope round the lower strut.

15. Lift in the upper strut and carefully release the rope in the lower strut to counteract the pendulum movement that occurs.

ATLET SERVICE MANUAL

Mast system to: A -15000

Mast

6.9

39 40 42

41

14 15 16 17 18 10 9 8 3

4

2

76

5

22 19 21 20 43 13

44

12

11

45 1

52 46 47

38 37

48 10 4 2

9

3

8

76

5

28 23

27 29 24 25 26 30

31

32 49

33

50

51 23

23

1

27 24 24

C 86.1

34 35

36

25

30 26

28 29 32 31 33

Figure 6.5 TV to: A-15000

Mast system to: A -15000

ATLET SERVICE MANUAL

6.10

Mast

6.3.8

Dismantling the DT mast

1

Lift the forks approx. 1 m and unscrew the stop bolt in the inner mast channel, pos. 58 figure 6.6.

2.

Remove the shims and slide lugs, pos. 45 and 46.

3.

Run the support arm into a pallet, put another pallet on the other, and lower the fork carriage down on to them until the chains go slack.

4.

Remove the pin that fastens the chain in yoke. Place the chains on the fork carriage.

5.

Lift until the fork carriage comes free from inner mast, and reverse the truck to the place for dismantling the mast.

6.

Place a wooden block on the support arm between the outer mast profiles, and lower the inner mast so that it stands on the wooden block.

7.

Remove the pin, pos. 43, that holds the middle chain in the attachment on the inner mast’s lower strut.

8.

Attach a lifting device on the inner mast’s upper strut, lift the inner mast half way, and remove the lifting stop, pos. 54.

9.

Tie a rope round the inner mast’s lower strut and hitch it round the front part of the overhead guard (between the flat bars).

10. Lift the inner mast until its lower rollers, pos. 4, meet the intermediate mast’s rollers, pos. 4. Stretch the rope round the lower strut and run the overhead crane in the lengthwise direction of the support arm from the machine, while lowering the inner mast’s upper section at the same and stretching the rope round the lower strut.

11. When the inner mast is horizontal in relation to the outer mast, it can be lifted out by stretching the rope round the lower strut.

12. Lift in the upper strut and carefully release the rope in the lower strut to counteract the pendulum movement that occurs.

13. Secure the cylinder with a rope, and release the lock ring that fastens the cylinder’s piston rod in the yoke.

14. Lift the intermediate mast by means of the cylinder, place a wooden block between the outer mast profiles, and lower the intermediate mast so that it rests on the wooden block.

15. Release the cylinder’s hydraulic hoses and plug them, release the cylinder’s lower retaining screw, and lift out the cylinder.

16. Lift out the intermediate mast in the same way as the inner mast.

ATLET SERVICE MANUAL

Mast system to: A -15000

Mast

36

6.11

37 38 50

35

52 51

3

4

3

4

2

53

2 39

40 31

4

33

32

2

3

15 11 10 9

42

8

34 14

41

13

7

6

12

43 44 45

54 55

46

30 47 48

15 5

58

49

54 55 14

4

4

3

3

2

13

12

1 2

21 16

20 22 17 18 23

24

19

25 56

26

57 16 16

1

20 17

21

17

C 53.3

27

28

29

18

23 19

24

22 25

26

Figure 6.6 DT to: A-15000

Important!

When assembling make sure that the wear lugs, pos. 15, are fitted before lifting in the inner mast.

Mast system to: A -15000

ATLET SERVICE MANUAL

6.12

Mast

6.3.9

Dismantling the T mast

1

Lift the forks approx. 1 m and unscrew the stop bolt in the inner mast channel, pos. 40 figure 6.7.

2.

Remove the shims and slide lugs, pos. 29 and 30.

3.

Run the support arm into a pallet, put another pallet on the other, and lower the fork carriage down on to them until the chains go slack.

4.

Remove the pin that fastens the chain in fork carriage’s chain bolts.

5.

Lift until the fork carriage comes free from inner mast, and reverse the truck to the place for dismantling the mast.

6.

Place a wooden block on the support arm between the outer mast profiles, and lower the inner mast so that it stands on the wooden block.

7.

Secure the cylinder with a rope, and release the upper retaining nut, pos. 34, on the cylinder.

Important!

Make sure that the cylinder does not drop forward.

8.

Release the cylinder’s hydraulic connections and plug them in both ends, and then release the cylinder’s lower retaining screw, pos. 39.

9.

Release the rope and lift off the cylinder.

10. Remove the side thrust rollers, pos. 4, attach a lifting device on the inner mast’s upper strut, lift the inner mast half way, and remove the lifting stop, pos. 37.

11. Hitch a rope round the inner mast’s lower strut and hitch it round the front part of the overhead guard (between the flat bars).

12. Lift the inner mast until its lower rollers, pos. 4, meet the outer mast’s rollers.

13. Stretch the rope round the lower strut and run the overhead crane in support leg’s lengthwise direction from the machine, while lowering the inner mast’s upper section at the same time and stretching the rope round the lower strut.

14. When the inner mast is horizontal in relation to the outer mast it can be lifted out by stretching the rope round the lower strut; lift in the upper strut, and carefully release the rope in the lower strut to counteract the pendulum movement that occurs.

Important!

When assembling make sure that the wear lugs, pos. 9, are fitted before lifting in the inner mast.

ATLET SERVICE MANUAL

Mast system to: A -15000

Mast

6.13

1 10 11

12

34 35

4

2

2

3

3 4

27 9 5

36

28 30 37

29 31 32

8

40

33

7

6

1

4 3

13

2 14

23 20

21

22

17 18

38

19

39

16 15

13 1

14

C 51.2

24

25

26

Figure 6.7 T to: A-15000

Mast system to: A -15000

ATLET SERVICE MANUAL

6.14

6.4

Mast

Mast system from: A -15000 0

6.4.1

Dismantling the DTFV mast

1

Lower the fork carriage onto a European pool pallet, or the like, so that the intermediate cylinder’s lift chain slackens.

2.

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and remove the pin between the bolt and chain.

3.

Lift until the fork carriage comes free from the inner mast.

4.

Place a wooden block on the support arm between the outer profiles so that it comes under the intermediate cylinder. Lower the inner and intermediate mast so that the inner mast rests on the wooden block and the outer chains slacken.

5.

Remove the two outer chains by removing the pins in the upper chain attachment.

6.

Release the hoses that run in the mast from block in the outer mast, and plug them.

7.

Remove the runner for the hoses from the intermediate mast.

8.

Remove the runner for the chains from the intermediate mast.

9.

Unscrew the screw for the lifting stop.

10. Lift the inner mast straight up until the inner mast’s lower support rollers and the intermediate mast’s support rollers meet, and then pull the inner mast forwards to release it from the intermediate mast.

11. Remove the upper retaining screws for the side cylinders.

12. Lift out the intermediate mast in the same way as the inner mast.

ATLET SERVICE MANUAL

Mast system from: A -15000

Mast

6.15

4 6

5

45

7

46

47

2 44

48 41 43

49 52 51

13 20 21 22

45 14

50

23 47

42

24

52 10 12

11

9 3

9

10 11 14 15

16 17

1

27 28 35

30 9 33

31 34 27 1

28

C 160.1

40

39

38

Figure 6.8 DTFV from: A-15000

6.4.2 1

Dismantling the TFV mast

Lower the fork carriage onto a European pool pallet, or the like, so that the intermediate cylinder’s lift chain slackens.

Mast system from: A -15000

ATLET SERVICE MANUAL

6.16

Mast

2.

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and remove the pin between the bolt and chain.

3.

Lift until the fork carriage comes free from the inner mast.

4.

Lower down the mast to its bottom position.

5.

Release the hose from the outer mast and plug it. Remember to remove the bundling strips.

6.

Remove the upper retaining screws for the side cylinders.

7.

Lift the inner mast straight up until the inner mast’s lower support rollers and the outer mast’s support rollers meet, and then pull the inner mast forwards to release it from the outer mast.

ATLET SERVICE MANUAL

Mast system from: A -15000

Mast

6.17

13 14 44

2

20

41 21 22 23 42

24 43 12

10 11 9 14 15 16 17 1 27 28 35

30 32 33

31 34 27 1

28

C 157.1

40

39

38

Figure 6.9 TFV from: A-15000

Mast system from: A -15000

ATLET SERVICE MANUAL

6.18

Mast

6.4.3

Dismantling the TV mast

1

Lower the fork carriage onto a European pool pallet, or the like, so that the lift chains slacken.

2.

Release the lift chains from the outer mast by removing the upper pins.

3.

Lift until the fork carriage comes free from the inner mast.

4.

Lower down the mast to its bottom position.

5.

Remove the upper retaining screws for the side cylinders.

6.

Lift the inner mast straight up until the inner mast’s lower support rollers and the outer mast’s support rollers meet, and then pull the inner mast forwards to release it from the outer mast.

ATLET SERVICE MANUAL

Mast system from: A -15000

Mast

6.19

3 5

4 6

13 14

20 21 22

45

2

50

23 47

24

12

9

10 11

14 15 16 17 1 27 28 35

30 32 33

31 34 27 1

28

C 154.1

40

39

38

Figure 6.10 TV from: A-15000

Mast system from: A -15000

ATLET SERVICE MANUAL

6.20

Mast

6.4.4

Dismantling the T mast

1

Lower the fork carriage onto a European pool pallet, or the like, so that the intermediate cylinder’s lift chain slackens.

2.

Release the lift chain from the intermediate cylinder by releasing the chain bolt, and remove the pin between the bolt and chain.

3.

Lift until the fork carriage comes free from the inner mast.

4.

Lower down the mast to its bottom position.

5.

Secure the lift cylinder so that it cannot move sideways.

6.

Remove and plug the oil pipes.

7.

Release the lift cylinder’s upper retaining bolts from the inner mast.

8.

Remove the lower retaining screw.

9.

Carefully lift up the inner mast until it can be lifted out from the cylinder.

10. Lift the inner mast straight up until the inner mast’s lower support rollers and the outer mast’s upper support rollers meet, and then pull the inner mast forwards to release it from the outer mast.

ATLET SERVICE MANUAL

Mast system from: A -15000

Mast

6.21

4

8 5 6 7

9

10

1

11 13 14 20

15 17 18 2 3

16 19

13 1

14

C 150.1

26

25

Figure 6.11 T from: A-15000

Mast system from: A -15000

ATLET SERVICE MANUAL

6.22

6.5

Mast

Fork carriage 0

Different fork arrangements are mounted on the back of the fork carriage. From basic forks to complex units with telescopic forks.

6.5.1

Adjusting to: A -15000

1

The side thrust rollers should have a clearance of 1.0 mm to the roller surfaces.

2.

Adjust the four cams, pos. 12, so that they have a play of 1.0 mm to the roller surfaces.

Warning!

The lowering speed can be affected if the tightening torque is excessive. The mast sections can even lift in the wrong order.

18

21

19 20

6 5

9

8 7

4

15

11 14

10 13

16 17 22

pC 79.1

12 7 8

9

Figure 6.12 Fork carriage to: A-15000

6.5.2

Adjusting from: A -15000

1

The side rollers should have a play of 1.0 mm to the roller surfaces.

2.

The lateral play is adjusted by adjusting the number of shims behind the thrust rollers, or by replacing the rollers, pos. 21, 22.

ATLET SERVICE MANUAL

Fork carriage

Mast

6.23

10

13

11

12 16

17

1

20 21 22

C 151.1

Figure 6.13 Fork carriage from: A-15000

6.5.3

Dismantling

1

Remove the stop screw in the inner mast. (Not from: A -15000)

2.

Lower down the fork carriage on a European pallet, or the like.

3.

Remove the lift chain.

4.

Lift up the inner mast with truck’s standard hydraulic system until the fork carriage is released.

Important!

Observe great caution!

5.

Fork carriage

Reverse the truck away.

ATLET SERVICE MANUAL

6.24

Mast

6.5.4

Dismantling the fork carriage ATF

The fork carriage only needs to be lifted out of the frame when replacing fork carriage rollers. To lift out, see the instructions for dismantling the type of frame the truck is equipped with.

1

Lift the fork carriage to a suitable height to dismantle the over-cogging protection, pos. 82 figure 6.14, on the back of the fork carriage.

2.

Lower the fork carriage to a suitable height to achieve a comfortable working position; make sure that the forks are fully withdrawn.

3.

Pull the battery plug out from the electrical panel plug to disconnect the current to the truck’s electrical system.

4.

Release the flexible cable to the fork drive motor by loosening the two nuts that hold the motor’s end head, and then remove the cables connections to the motor.

5.

Release the bolts, pos. 55, just enough to be able to adjust the chain tensioning bolt, pos. 40. Screw the bolt to the left so that the chain, pos. 69, slackens and the chain lock, pos. 85, can be removed.

6.

Loosen the bolts, pos. 55, completely and lift off the drive assembly.

7.

Loosen the screws, pos. 3 and 4, on the fork sleeves and pull off the forks.

8.

Release the chain adjuster, pos. 9.

9.

Remove the chain lock, pos. 6, and remove the chains, pos. 5.

10. Remove the sprockets in the inner forks.

11. Remove the side thrust rollers, pos. 30 and 35.

12. Remove the outer lock rings holding the side bearings for the shaft, pos. 63.

13. Remove the middle bearing, pos. 68. Drive the shaft to one side so that the side bearing presses out from the fork carriage. Remove the bearing and lift the shaft out from the fork carriage.

14. Note the order in which the gear, lock rings and spacers are fitted, and work them off.

ATLET SERVICE MANUAL

Fork carriage

Mast

6.25

2 3 4

5 6

11

12

6 10 7

14

8

9

1

13 26 24

80

30 25

15 27 28

20

21 22

63

81

16

23 39

24

37

35

82

40 41

38 26

83 84

27

28

42

71

56

43

70 53

44

49 54

59 85

52 51 48 50 97 97

60 57

58

54

85

69

55 54

96

45 46

47

91

59

88 87 59

95

60

76

58

66

65 54 90

65

66

67

65

90

65

81

63

68

90 63 86

59

99

62

98

61

C 95.1

Figure 6.14 Fork carriage ATF

Fork carriage

ATLET SERVICE MANUAL

6.26

Mast

6.5.5

Assembling the fork carriage ATF

1

Fit the sprockets in the inner forks. Lightly grease the bearing inside and outside before fitting.

2.

Fit the rear shaft with sprocket, stop rings and bearing housing. Check that the shaft is not misaligned by rotating it by hand at least one turn in each direction.

3.

Fit and adjust the fork chains so that they run parallel with the sprockets, and so that they give 2-4 mm in the middle. Lock the sprockets, stop rings and chain tensioners. Lightly grease the chains along their entire length.

4.

Fit the over-cogging guard.

5.

Fit and adjust the roller attachments by using a fork sleeve, so that the play is less than 0.3 mm. Make sure that the forks are centred on the inner forks.

Remember to lock with the screws.

6.

Lightly grease all the roller surfaces along their entire length, and fit the fork sleeves.

7.

Fit the complete motor. Fit and adjust the lower motor chain so that it runs parallel between the sprockets, and so that it gives 2-4 mm in the middle.

Lock the motor attachment and the sprocket. Lightly grease the chain along its entire length.

8.

Remove the plug in the gearbox and check the oil level, which should reach to the centre of the output shaft. Replenish if necessary.

6.5.6

Checking the fork carriage ATF truck

Test run the fork carriage and check that: • the forks do not jam • the forks go fully in and out • the chains run parallel between the sprockets • there is no abnormal noise • the overload clutch slips in the end positions

6.5.7

Overload clutch

The overload clutch is a unit that safeguards against overloading the components that drive the forks in and out.

The torque that the overload clutch can transfer is limited by the force the pressure springs, pos. 3, transfer to the pressure plate, pos. 4, and the brake linings, pos. 8, to the sprocket, pos. 10 figure 6.15.

The spring tension is not adjustable since the tensioning nut, pos. 5, should be fully screwed in and locked with stop screws. The bearing, pos. 9, and sprocket, pos. 10, should be lightly lubricated with cold-resistant grease (-35°C).

ATLET SERVICE MANUAL

Fork carriage

Mast

6.27

Warning!

There must not be any grease on the brake linings.

If the sliding clutch is damaged, it must be completely replaced.

3 9 7

5 6 10 1

8

2

4

p60092b.eps

Figure 6.15 Overload clutch

Fork carriage

ATLET SERVICE MANUAL

6.28

6.6

Mast

Forks 0

6.6.1

Adjusting forged forks

The inner and outer masts should be lowered.

2.

Adjust the two outer chains so that the mast hangs a little in the chains.

3.

Adjust the middle chain so that the fork head is 5 ± 2 mm from the ground.

5 2

1

SM 075.1

Figure 6.16 Forks

6.6.2

Adjusting welded forks

1

The inner and outer masts should be lowered.

2.

Adjust the two outer chains so that the mast hangs a little in the chains.

3.

Adjust the chains so that the fork height is as shown in the table 6.4 below.

Fork height in lowered position Table 6.4 Machine type

Mast type

AJN / ASN

narrow gauge broad gauge

ATF

ATLET SERVICE MANUAL

Min

Max (mm)

controlled by ground clearance when driving

95 60

ground clearance when driving

90

Forks

Mast

6.6.3

6.29

Fork test 0

Seven inspection points are included in the fork test. If the forks fail to meet any of the points, the machine must be taken out of service. If the customer is not prepared to do this, it should be written in the report that “The forks do not comply with the requirements in SS-ISO/ 5057”. When the customer subsequently signs the service order, they bear the responsibility for the defective forks.

Straightness of the blades and shanks: Deviations from the straightness of the carrier surface and the support surface must not exceed 0.5% of the length of the blade and shank. See figure 6.18.

L = 1150 mm, max deviation 5.75 mm.

L = 950 mm, max deviation 4.75 mm.

L = 800 mm, max deviation 4.00 mm. h = 492 mm, max deviation 2.46 mm. h = 464 mm, max deviation 2,32 mm.

Marking

Diference in height between fork arm tips

SM 020.3E

Figure 6.17 Forks designations

Thickness Shank Tip Thickness

Hook Blade Heel L=Length

SM 021.3E

Figure 6.18 Forks designations

Forks

ATLET SERVICE MANUAL

6.30

Mast

Crack formation: Check whether the forks are cracked. Check carefully around the heel and hooks. See figure 6.17 and figure 6.18.

Wear: Check the forks for wear, especially around the heel. The blade thickness must not be thinner than 90% of the original thickness.

The original thickness is found by: 1

Reading the markings on old forks.

2.

Measuring the blade thickness in the centre of the shank.

3.

Contacting Atlet for information about blade thickness.

Fork angle: The angle between the blade and the shank may be max 93 degrees.

Difference in height between the tips of the forks: The difference in height between the tips must not exceed 3% of the blade length. See figure 6.17.

Locking device: Check that the locking device works.

Markings: The fork markings should be explicit and include the lifting capacity in kg for one fork and the centre of gravity distance in mm. See figure 6.17.

ATLET SERVICE MANUAL

Forks

Mast

6.7

6.31

Checking the lift chains 0

For safety reasons all the lift chains should be checked at maximum intervals of 500 hours of operation.

If a lift chain fails to be approved in any respect, the complete chain must be replaced; it is not permitted to replace parts of a lift chain.

• Check that the chain is clean. Measure when the forks are unloaded.

• Measure the chain’s elongation; measure over the 25 links that go over the pulley wheel, since elongation is normally greatest here. Compare with the measurements below. If the chain’s elongation is more than 2 % it should be replaced.

P

G

P

SM 169.1

Figure 6.19 Chain dimensions Table 6.5 Chain dimension (inches)

P Dimension (mm)

Measured over 25 links New chain (mm)

Max over 25 links 2% elongation (mm)

1/2

12.70

317.5

323.8

5/8

15.875

396.9

404.8

3/4

19.05

476.2

485.8

1

25.4

635.0

647.7

1 1/4

31.75

793.7

809.6

1 1/2

38.10

952.5

971.5

• Measure the height of the chain’s link plates, dimension G in figure 6.19. Max wear is 5%. Measure the original height where the chain is not worn as a comparison.

Example: A chain has an original plate height of 23.2 mm, and therefore the plate height should be at least 23.2 - 5% = 23.2 x 0.95 = 22 mm.

• Make sure than none of the pins in the plates have twisted, see figure 6.20.

Checking the lift chains

ATLET SERVICE MANUAL

6.32

Mast

A

B

SM 169.2

Figure 6.20 Twistwd pin • • • •

Make sure that there are no cracks in the plates.

Look for traces of mechanical damage or rust.

Check that the chain runs easily over the pulley wheel and does not jam.

Lubricate the chain after cleaning and inspection.

6.7.1

Regular maintenance

The chain should be kept clean.

Lubricant (see lubrication chart in section 1) must be regularly applied on the chain so that all working surfaces are constantly lubricated.

The chain should be kept in motion when lubricating to ensure that the lubricant penetrates the working surfaces between the link plates and pins. All excess lubricant should wiped off, but solvent must not be used.

If the chain runs dry it should be lubricated more often; this also applies if the truck is working in special environments such as cold stores, etc.

6.7.2

Re-fitting the chains

When chains are re-fitted it is important to align them correctly, and that there is no deterioration of the clearance.

ATLET SERVICE MANUAL

Checking the lift chains

Mast

6.8

6.33

Straddle lift 0

6.8.1

Adjusting

1

Place the truck on a level floor and lower the forks and straddle lift.

2.

Check that the distance between the floor and top of the forks corresponds with the table 6.6 below. Measure at four points on each fork tip and at the back of the fork.

3.

Check that the distance is the same between mast and guides. If necessary adjust to the same distance with the adjusting screws, both at the top and bottom.

4.

The lateral play in the mast should be 0-0.5 mm.

5.

Check that the forks are horizontal.

If the fork tips point upwards, the push rods should be shortened.

If the fork tips point downwards, the push rods should be extended.

6.

When the forks are parallel, check the height. The cylinders can be extended if it is not high enough.

7.

Test lift, and check that the straddle legs do not lift skew. If so, adjust the length of the cylinders until the best lifting movement is obtained.

8.

Check measure, and if necessary make further adjustments.

Table 6.6 Truck with straddle lift Distance to top of fork

Max 95 mm

Distance to top of support arm

Max 90 mm Min 85 mm

6.8.2

Straddle lift

Dismantling and assembling, T, TF, DT, DTF

1

Lift up the straddle legs with the truck. Place a block under the fork tips and lower down the straddle legs, whereby the load wheel lifts from the floor.

2.

Tap out the retaining pin through the shaft, pos. 24 figure 6.21, and drive out the shaft.

3.

Release the caps, pos. 38, and pull out the load wheel, push rods and thrust links together.

4.

Remove the lock rings from the shafts through the ends of the push rods, and tap out the shafts.

5.

Check for wear and replace damaged parts if necessary.

ATLET SERVICE MANUAL

6.34

Mast

6.

Assemble in the reverse order.

7.

Check the lifting movement. If the straddle legs pull at an angle they must be adjusted, see section 6.8.1 “Adjusting”.

7

8 9

16 13

14

11

15

53 52

10

12

55

51

21 56

17

48

3 18

19

2

20

39

1 38

40 22

4

35

6

5 33

36

54 37

38

41

34

42

50

49

23 31

24

25

30

19 19 26

29

27 28 32

47 19 43

56

46 8

45

9 44

C 89.2

Figure 6.21 Straddle lift T, TF, DT, DTF

ATLET SERVICE MANUAL

Straddle lift

Mast

6.8.3

Straddle lift

6.35

Dismantling and adjusting, TV, TFV, DTFV

1

Lift up the straddle legs with the truck. Place a block under the fork tips and lower down the straddle legs, whereby the load wheel lifts from the floor.

2.

Tap out the retaining pin through the shaft, pos. 24 figure 6.22, and drive out the shaft.

3.

Release the caps, pos. 38, and pull out the load wheel, push rods and thrust links together.

4.

Remove the lock rings from the shafts through the ends of the push rods, and tap out the shafts.

5.

Check for wear and replace damaged parts if necessary.

6.

Assemble in the reverse order.

7.

Check the lifting movement. If the straddle legs pull at an angle they must be adjusted, see section 6.8.1 “Adjusting”.

ATLET SERVICE MANUAL

6.36

Mast

7

8 9 16 13

14

15

11

10

12

54

21 25

17

53

3 18

19

2

20

48

50

49

51

52

1

22

38 39 40

23

41 4

5

6 37

19 36

24

31

46

27

26

47

28 32 19

58

19 34 30 33 29 29

57 42 43

59

55 56

35

C 99.1

Figure 6.22 Straddle lift TV, TFV, DTFV

ATLET SERVICE MANUAL

Straddle lift

Mast

6.9

6.37

Side stabilisers 0

6.9.1

Dismantling and assembling

1

Run out the stabilisers and switch off with the key. Relieve the hydraulic system by moving the hydraulic lever backwards and forwards between the end positions.

2.

Release the hoses to the cylinder, and plug to avoid oil leakage.

3.

Drive out the retaining pin, pos. 27, and shaft, pos. 28 figure 6.23. Release and remove the pin in the top end of the cylinder, and lift off the cylinder.

4.

Remove the cover over the microswitches, pos. 22.

5.

Drive out the retaining pin, pos. 15, and remove the cam, pos. 20.

6.

Drive out the retaining pin, pos. 12, and shaft, pos. 10. Lift off the stabiliser arm.

Important!

Make sure not to damage the microswitches.

7.

Remove the locking washer and nut that holds the wheel fork, and lift off the wheel fork.

8.

Check all parts. Replace or repair if necessary.

Side stabilisers

ATLET SERVICE MANUAL

6.38

Mast

1 2 3

3

1

4 6

5

7 8 10

9

11 24

15 25 26

21

11

12

22

23 27

29 28

20 13

31

28

14 18

32

19

33 34 33 16 17 35 40

36

37 38

37

36 39

C 73.1

Figure 6.23 Stabiliser to: W-9201

ATLET SERVICE MANUAL

Side stabilisers

Mast

6.39

4 8 2

9

1

5

10 29 25

11

30 31

15 12

32

21

11

24 22 27

20 23

13 14

28

18 33

19

34 33 16 17

35 40

36 37 38

37 36 39

C 37.2

Figure 6.24 Stabiliser from: W-9201

6.9.2

Assembling

Assemble and fit the side stabiliser in the reverse order. Check if any adjusting is necessary, see chapter 6.9.3, “Checking the side stabiliser,” on page 40.

Side stabilisers

ATLET SERVICE MANUAL

6.40

Mast

6.9.3

Checking the side stabiliser

1

Place the truck on a level surface.

2.

Extend the stabilisers slowly until the motor stops, and check the distance of the wheels from the floor. Compare with the values in the table 6.7 below.

3.

Pull in the stabilisers and check that the motor stops automatically when they are fully retracted. Check also the residual suspension. Compare with the values in the table 6.7 below.

4.

Fix a tape measure with zero at the top edge of one fork. Lift until the stabiliser switch in the mast breaks, i.e. until the mast stops, and measure the height. Compare with table 6.7 in section 10 Table 6.7 Check values for side stabilisers When the stabilisers are extended at full speed there should be no play between the floor and wheels when the pump motor has stopped. Irregularities in the floor are absorbed by the built-in spring in the top of the cylinder.

Residual suspension with fully extended stabilisers, see A, figure 6.26.

ATLET SERVICE MANUAL

10-12 mm

Side stabilisers

Mast

6.41

A

SM 074.2

Figure 6.25 Check points for side stabilisers

6.9.4

Adjusting the side stabilisers

• Mechanical adjusting is made by adjusting the top end of the cylinder.

• If the motor does not stop in the end positions, adjust the microswitches; see section 10.

Side stabilisers

ATLET SERVICE MANUAL

6.42

6.10

Mast

Lift cylinders 0

All the thrust rollers and side thrust rollers in the mast bear the load. The brass screws and blocks absorb any play in the mast. The mast’s cams should be adjusted as shown in section 6.2.1.

6.10.1

Adjusting the cylinder attachment in the mast

1

Lower the mast and slacken the chains.

2.

Loosen the brass screws, pos. 32, figure 6.26, approx. 5 - 10 mm.

3.

Adjust the attachment of the outer cylinders with the top nut, pos. 10 figure 6.27. Adjust both cylinders equally.

4.

If there is sufficient movement in the cylinder’s attachment, the rollers will be in contact with the mast’s running surface at all lifting heights, even if the brass screws are not tightened.

5.

Function test the lifting movement.

6.

Tighten the chain and check that the rollers are still in contact with the running surface.

The cylinder attachment should be flexible.

7.

Adjust the mast as shown in section 6.3.

1

2

3 4 5 6

30

31 32 p2C 200.3

Figure 6.26 Mast top to: A-15000

ATLET SERVICE MANUAL

Lift cylinders

Mast

6.43

10

SM 094.2

Figure 6.27 Cylinder attachment

6.10.2

Lift cylinders

Adjusting the cylinder attachment in the mast from A - 15000

1

Lower the mast and slacken the chains.

2.

Adjust the attachment of the outer cylinders with the top nut, pos. 10 figure 6.27. Adjust both cylinders equally.

3.

If there is sufficient movement in the cylinder’s attachment, the rollers will be in contact with the mast’s running surface at all lifting heights.

4.

Function test the lifting movement.

5.

Tighten the chain and check that the rollers are still in contact with the running surface.

6.

The cylinder attachment should be flexible.

7.

Adjust the mast as shown in section 6.3.

ATLET SERVICE MANUAL

6.44

ATLET SERVICE MANUAL

Mast

Lift cylinders

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Steering 7.1 Introduction................................................................................................................... 7.1 7.2 Mechanical steering ..................................................................................................... 7.5 7.2.1 Adjusting the steering chains ........................................................................................7.5 7.2.2 Procedures for heavy steering .......................................................................................7.5 7.3 Electronic steering (ACC) ............................................................................................ 7.6 7.3.1 Servo steering unit, functions .......................................................................................7.6 7.3.2 Servo steering unit, settings ..........................................................................................7.7 7.3.3 Factory setting, electric steering ...................................................................................7.8 7.3.4 Servo steering unit, diagnostics ....................................................................................7.9 7.3.5 Trouble shooting .........................................................................................................7.10 7.3.6 Check tachometer .......................................................................................................7.10 7.3.7 Servo motor, replacing carbon brushes .......................................................................7.11

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Steering

7.1

Edition 2001A

7 Steering 00000000

7.1

Introduction 0

The steering system on A-86 machines is mechanical or electrical.

SM 076.1

Figure 7.1 Outline diagram, steering On trucks manufactured before 1991, week 20, the steering power from the steering wheel is transferred through an intermediate gear and a steering shaft directly to the steering drive wheel, see figure 7.2. By changing the design of the intermediate gear it is possible to obtain reversed steering.

SM_A_07_e_2001a.fm

Introduction

ATLET SERVICE MANUAL

7.2

Steering

Figure 7.2 Steering to: W-9120

ATLET SERVICE MANUAL

Introduction

Steering

7.3

After week 20, 1991, the intermediate gear is designed with chains and sprocket, see figure 7.3. The steering power is transferred from the steering wheel through a steering gear designed with chain wheels mounted in a bearing housing, after which the power continues through a steering shaft and chain gear to the steering drive wheel. By changing the position of the intermediate gear it is possible to obtain reversed steering.

Figure 7.3 Steering from: W-91201 From 1996, week 40, electric steering is also available as a standard accessory, see figure 7.4. The steering movement is transferred completely electronically, without mechanical connection between the steering wheel and wheel. The system consists

Introduction

ATLET SERVICE MANUAL

7.4

Steering

of steering wheel, steering servo unit and servo motor. Built into the steering servo unit there is a monitoring system, which stops the truck if an electrical fault occurs in the steering system.

14

12

13

17 18 19 20 23

21 j 48

24

49 50 51 48

52

26 1

27

34 22

25

3

28 29

4 2

30 5 31 5

29 28

32

39

7

40

33 34 36 35

6

8 41 42 37 38

9

43 10

14

44

11

45 46

8 47 9 15

16

12 13

pD 24-1.eps

Figure 7.4 Servo steering from: W-9640

ATLET SERVICE MANUAL

Introduction

Steering

7.2

7.5

Mechanical steering 0

7.2.1

Adjusting the steering chains

On trucks manufactured before 1991, week 20, the steering chain is adjusted by releasing the chain tensioner, pos. 42 figure 7.2, and moving it in its rectangular groove.

On trucks manufactured after 1991, week 20, the steering chain is adjusted by releasing the adjusting screw, pos. 32 figure 7.3, and turning it.

Important!

Remember to lock the adjusting screw!

7.2.2

Procedures for heavy steering

If the steering is very heavy after replacing the drive wheel, check the shimming of the truck’s castor wheel and that the truck does not lean; see shimming of drive wheel, section 4.

If the steering becomes heavy after the truck has been moved to another building, this may depend on the flooring.

Since the truck is equipped a rubber drive wheel it can be replaced with one of Vulcolan, which reduces friction to the floor during turning but also of course during driving.

Mechanical steering

ATLET SERVICE MANUAL

7.6

7.3

Steering

Electronic steering (ACC) 0

7.3.1

Servo steering unit, functions Table 7.1 Switch function (dipswitch) No.

1

Function Current limit

2 3

IR compensation

4 5

Sensitivity

6 7 8

Table 7.2 Indicator lamp LED No.

Indicates the following when on

1

Everything OK

2

End position

3

End position

4

Fault

5

Fault

RE1 K2

1 2 3

4

5 6 7 OFF

M1

M2

1

RELAY

+

8 9 10

11 12 13

SW1 1 2 3 4 5 6 7 8

ON

2

LIN

3

LIN

4

ERROR

5

ERROR

K1

SM 033.1

Figure 7.5 Servo steering unit

ATLET SERVICE MANUAL

Electronic steering (ACC)

Steering

7.3.2 1

7.7

Servo steering unit, settings

Current limiting to the motor (regulates the servo motor’s torque).

The limiting value can be set to four different levels through dipswitch 1 and 2. If the torque is too low the steering movement will lack force and be slow, and lead to delays when the steering wheel is turned quickly. Settings in accordance with the table 7.3 below.

Table 7.3 Current limiting

Position dipswitch 1

Position dipswitch 2

15A

Open (off)

Open (off)

20A

Open (off)

Closed (on)

25A

Closed (on)

Open (off)

30A

Closed (on)

Closed (on)

The current limit can be set to maximum level if: • The motor’s rating data is less than the top current.

• The torque produced exceeds the mechanical parts.

1.

IR compensation (the capacity of the motor to follow the turning of the steering wheel): The compensation can be set to four different levels with dipswitch 3 and 4.

If the compensation is too low the motor will not follow slow movements of the steering wheel, while if it is too high the motor will oscillate and cause overheating. Settings in accordance with the table 7.4 below: Table 7.4 IR compensation

Position dipswitch 3

Position dipswitch 4

0%

Open (off)

Open (off)

33 %

Closed (on)

Open (off)

67 %

Open (off)

Closed (on)

100 %

Closed (on)

Closed (on)

Note!

The switch is open when it is in the off position.

1.

The tachometer’s sensitivity (ratio between speed, steering wheel/servo motor): The sensitivity can be set in 16 different levels with dipswitches 5, 6, 7 and 8.

If the sensitivity is too high the steering movement can be too powerful at high speeds, while with low sensitivity the steering becomes too slow. To obtain a good sensitivity level at both high and low speeds the unit is fitted with

Electronic steering (ACC)

ATLET SERVICE MANUAL

7.8

Steering

progressive steering. This means the sensitivity automatically increases with rapid steering wheel movements.

Settings in accordance with the table 7.5 below: Table 7.5 Sensitivity

Position dipswitch 5

Position dipswitch 6

Position dipswitch 7

Position dipswitch 8

±1.3V

Closed (on)

Closed (on)

Closed (on)

Closed (on)

±1.6V

Open (off)

Closed (on)

Closed (on)

Closed (on)

±1.9V

Closed (on)

Open (off)

Closed (on)

Closed (on)

±2.3V

Open (off)

Open (off)

Closed (on)

Closed (on)

±2.6V

Closed (on)

Closed (on)

Open (off)

Closed (on)

±2.9V

Open (off)

Closed (on)

Open (off)

Closed (on)

±3.2V

Closed (on)

Open (off)

Open (off)

Closed (on)

±3.5V

Open (off)

Open (off)

Open (off)

Closed (on)

±3.8V

Closed (on)

Closed (on)

Closed (on)

Open (off)

±4.1V

Open (off)

Closed (on)

Closed (on)

Open (off)

±4.4V

Closed (on)

Open (off)

Closed (on)

Open (off)

±4.7V

Open (off)

Open (off)

Closed (on)

Open (off)

±5.0V

Closed (on)

Closed (on)

Open (off)

Open (off)

±5.3V

Open (off)

Closed (on)

Open (off)

Open (off)

±5.6V

Closed (on)

Open (off)

Open (off)

Open (off)

5.9V

Open (off)

Open (off)

Open (off)

Open (off)

7.3.3

Factory setting, electric steering Table 7.6 Switch

1

ON

2

OFF

3

OFF

4

ON

5

ON

ATLET SERVICE MANUAL

Electronic steering (ACC)

Steering

7.9

Table 7.6 Switch 6

OFF

7

ON

8

ON

7.3.4

Servo steering unit, diagnostics Table 7.7 Control connection 13 pins No.

1. In

Signal 24V

2.

Description Start/stop, internal supply Not connected

3. Out

Open

Error code no. 1

4. In

0V

Tachometer

5. In

24V

Negative direction

6. In

±1.5 to 9.5V

Reference voltage from tachometer

7.

Not connected

8. Out

24V

Safety relay

9. Out

Normal error indicating

10.

Not connected

11. In

24V

Positive direction

12. Out

Error code no. 2

13.

Not connected

Table 7.8 Power connection 4 pins In/out

Signal

Description

+ In

24V

Battery voltage +

- In

0V

Battery voltage -

M1 Out

Motor connection + / -

M2 Out

Motor connection - / +

Electronic steering (ACC)

ATLET SERVICE MANUAL

7.10

Steering

7.3.5

Trouble shooting Table 7.9

LED 1 Green

LED 2 Red

LED 3 Red

LED 4 Red

LED 5 Red

—

—

—

—

—

No control current

Check supply

ON

—

—

—

—

OK

None

ON

ON

—

—

—

Negative direction active

None

ON

—

ON

—

—

Positive direction active

None

ON

—

—

ON

—

Fault in tachometer circuit. Cable break, shortcircuit or wrong type of tachometer.

Check the cables and connections.

If these are OK, replace the tachometer! If this does not help, check that the correct tachometer is used.

ON

—

—

—

ON

Fault in the steering unit or in the motor circuit.

Cable break or short circuit.

Check cabling, connections, carbon brushes for servo motor, fuses and contactors. If these are OK, replace the servo motor or steering unit.

ON

—

—

ON

ON

Fault in steering unit.

Replace steering unit.

7.3.6

Indicates

Action

Check tachometer

The tachometer is checked by measuring the resistance with a digital measuring instrument.

1

Remove the cables to the tachometer.

2.

Connect the instrument to the tachometer.

3.

Read-off the value, it should be approx. 45.8 Ohm.

4.

If the resistance is infinite there is a break in the tachometer and it should be replaced, which should also give an error code on the control unit.

ATLET SERVICE MANUAL

Electronic steering (ACC)

Steering

7.11

pD 42.2

Figure 7.6 Tachometer

7.3.7

Servo motor, replacing carbon brushes

1

Remove the plastic plugs over the brushes.

2.

Pull out the brushes.

3.

Fit new brushes.

4.

Replace the plastic plugs.

2

1

pD 200.4

Figure 7.7 Servo motor

Electronic steering (ACC)

ATLET SERVICE MANUAL

7.12

ATLET SERVICE MANUAL

Steering

Electronic steering (ACC)

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Hydraulic system 8.1 Functional description ................................................................................................. 8.1 8.2 Hydraulic system – general regulations..................................................................... 8.3 8.2.1 Installation ....................................................................................................................8.3 8.2.2 Connections ..................................................................................................................8.3 8.2.3 Start up ..........................................................................................................................8.3 8.2.4 Installation instruction for pipe couplings ....................................................................8.4 8.3 Hydraulic oil, changing/draining................................................................................. 8.8 8.3.1 Oil change .....................................................................................................................8.8 8.4 Air filter, replacing...................................................................................................... 8.10 8.5 Filter insert, replacing ................................................................................................ 8.11 8.6 Valves, AJN / ASN / ATF ............................................................................................ 8.12 8.6.1 Lowering brake valve, general ....................................................................................8.12 8.6.2 Lowering brake valve, dismantling and assembling ...................................................8.12 8.6.3 Setting the lowering brake valve ...............................................................................8.13 8.6.4 Hose rupture valve, general ........................................................................................8.14 8.6.5 Hose rupture valve, dismantling and assembling .......................................................8.14 8.6.6 Setting the hose rupture valve .....................................................................................8.15 8.6.7 Hydraulic valve, general .............................................................................................8.16 8.6.8 Hydraulic valve, dismantling and assembling ............................................................8.16 8.7 Hydraulic motor ASN / ATF ....................................................................................... 8.19 8.7.1 Dismantling .................................................................................................................8.19 8.8 Hydraulic motor AJN / ATF........................................................................................ 8.21 8.8.1 Dismantling .................................................................................................................8.21 8.8.2 Checking the lift motor AJN/STF ...............................................................................8.21

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

8.9 Stabiliser cylinders ASN / AJN.................................................................................. 8.23 8.9.1 Dismantling and assembling ....................................................................................... 8.23 8.9.2 Spring unit, dismantling and assembling .................................................................... 8.24 8.9.3 Dismantling and assembling, gaskets ......................................................................... 8.25 8.10 Hydraulic diagram .................................................................................................... 8.26

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Hydraulic system

8.1

Edition 2001A

8 Hydraulic system 00000000

Note!

All work with the hydraulic system should be carried in pressureless state and in a clean environment.

8.1

Functional description The driver operates a lift lever which actuates a microswitch, which in turn actuates the lift motor by means of a contactor. The lift lever also controls a control value, which controls an oil flow to the cylinder performing the work. In the control valve there is a pressure limiting valve, which limits the maximum hydraulic oil pressure.

The lift cylinder has a lowering brake valve, which is placed between the control valve and the cylinder. On certain cylinders there is also a hose rupture valve, which provides protection from accidents during uncontrolled oil discharge.

SM_A_08_e_2001a.fm

Functional description

ATLET SERVICE MANUAL

8.2

Hydraulic system

55

34 32

35

31 43

54

42

61

33

62

29 30

28

22

61 35

26 45 39

60

66

66 53

24

25

38

52 51

63

50 58

21 65 59

37

64

57 56 11 36

12 11

4

2

7

68 69

13

9

10

8

17

70

6 5

71

1 2

4

76

72 16

E 62.5

2 3

73

15 75 74

Figure 8.1 Hydraulic system

ATLET SERVICE MANUAL

Functional description

Hydraulic system

8.2

8.3

Hydraulic system – general regulations 0

Important!

Cleanliness during all work with hydraulic components is of the greatest importance for system’s operating safety and service-life. The following should be taken into consideration: • Dirt particles must not get into components.

• Do not use cloths that release fibres or particles.

• Only use clean tools.

• Carefully clean tanks, pipes and hoses before installation.

• Welded or hot-bent pipes must be pickled (cleaning with acid bath) and washed before they are built in.

• The oil tank must be closed and provided with an efficient air filter to prevent dirt contaminating the hydraulic system.

• Sealing compounds such as flax, cement or thread tape are not permitted.

• Take into consideration the specified operating data.

• Do not exceed permitted pressures and volume flows.

• Do not exceed or go below the specified temperature range.

• Pay attention to specified electrical voltages and power consumption.

8.2.1

Installation

To prevent dirt and corrosion in the hydraulic system all hydraulic components should be provided with plastic plugs in the connections before they are delivered.

Only remove these plugs just before the component is to be installed in the machine.

Retaining screws and connections must correspond with those on the drawing.

Retaining screws should not be tightened with a higher torque than what is specified on the drawing. If such specifications are lacking the torque should not exceed the torque stated in section 1.

8.2.2

Connections

Couplings should be fitted in accordance with the tightening torque stated in section 1. We recommend couplings with elastic seals. Such couplings are necessary for proportional valves. Ring couplings do not seal at the low torque generally applicable for proportional valves.

Connect pipes and hoses in accordance with the hydraulic diagram. Pay attention to the connection designations. Do not use force; avoid building-in tensions in pipes, etc.

8.2.3

Start up

Check that everything is connected in accordance with the hydraulic diagram. Set the pressure limiting valves down to a very low pressure if they are not sealed. Start up with low pressure and volume flows.

Hydraulic system – general regulations

ATLET SERVICE MANUAL

8.4

Hydraulic system

Test the function and tightness of the system. Clean the system by allowing oil to pass over the filter a while, without loading the system (replace the filter insert at the recommended intervals). Check the oil level. Set the pressure and volume flows slowly to the values they should have. Check the connected measuring equipment regularly, where appropriate. Pay attention to the noise level; abnormal noise implies defects. Test during variable loads that components are correctly fitted, and that the system is tight.

Warning!

In the event of return equipment to the manufacturer, protect polished surfaces from damage and dirt by covering them with foil and protective paper. Fit plastic plugs in all connections. Send the complete components, not loose parts.

8.2.4

Installation instruction for pipe couplings

To achieve a safe and tight connection when installing pipe couplings in the hydraulic system, the following points should be taken into consideration: 1

The pipe should be cut at right angles by means of a pipe cutter, after which it is deburred internally and externally, and carefully cleaned.

Important!

When using a pipe cutter the end of the pipe becomes skew, with the formation of substantial burrs internally and externally. It is therefore important to straighten the end of the pipe and remove the burrs, both internally and externally.

PS 001 e

Cut the pipe right angled and remove burrs

Figure 8.2 Cutting of pipes

PS 002

Figure 8.3 Pipe cutter

ATLET SERVICE MANUAL

Hydraulic system – general regulations

Hydraulic system

8.5

2.

Oil in the thread and ring (not grease). Put the nut and ring over the pipe end as shown in the figure 8.4. If the ring cannot be worked over the pipe end it must absolutely not be enlarged. File down the pipe end instead.

3.

Small pipe dimensions can be fitted directly in the coupling connected to the machine part. Screw the nut by hand until it lies flush with ring, press the pipe towards the shoulder in the coupling’s cone, and tighten the nut a ¾ turn.

Important!

The pipe must not follow round.

PS 003

Figure 8.4 The ring will now have gripped the pipe, and no longer needs to be pressed against the shoulder. Complete the fitting with an additional ¾ turn of the nut.

The ring has now cut into the pipe and in front of the ring there is a visible swelling of the pipe material.

4.

Larger pipe dimensions and couplings in free pipes are preferably fitted by placing the coupling body in a vice. The U-ring spanner should be 15 times the nut width (can be extended with a piece of pipe). Otherwise fit according to point 3.

If several couplings of the same type are to be fitted, make sure that each pipe end goes in the same coupling cone it was previously fitted in.

Hydraulic system – general regulations

ATLET SERVICE MANUAL

8.6

Hydraulic system

One mark on the nut will make it easier to follow recommended tightening torque.

PS 004e

Figure 8.5 Fitting is simplified if the nut is loosened and oil is applied between the friction surfaces.

5.

After fitting, release the cap nut and check that the ring has pressed up a visible swelling in the area in front of it. If not, give it another short turn. It is of no importance whether the ring can be turned.

Important!

Repeated fitting: After each dismantling the nut should be fitted without extension of the U-ring spanner, and without excessive force.

visible bank

PS 006e

Figure 8.6

ATLET SERVICE MANUAL

Hydraulic system – general regulations

Hydraulic system

6.

8.7

If the pipe is to be bent after a coupling, the straight pipe end should have a length of at least 2 nut heads, H. Long and heavily loaded pipes should be provided with pipe clips.

H 2H

PS 007

Figure 8.7 7.

Final assembly should be done with at least 1 turn of the nut from the point where it cannot be turned by hand.

Hydraulic system – general regulations

ATLET SERVICE MANUAL

8.8

8.3

Hydraulic system

Hydraulic oil, changing/draining 0

Intervals: After 250 hours of operation: The hydraulic oil filter and air filter to the hydraulic oil tank should be replaced after no more than 250 hours of operation. Replacing the hydraulic oil filter refers to those types of trucks that have replaceable filters. If there is a magnet together with the filter, this should be carefully cleaned. Cleaning of the suction filter refers to those types of trucks that have metal suction filters.

After every 1000 hours of operation: Changing of the hydraulic oil and replacing the oil filter and air filter after 1000 hours of operations, or once every year (whatever is first).

If the hydraulic oil has been heated over 60 degrees Celsius the oil and the filter should be immediately replaced since its lubricating properties will have been changed.

If it is suspected that the hydraulic oil has been contaminated with water (e.g. during work in cold store), it can be checked with the following simple test: 1

Use protective glasses, gloves and clothes, and observe the fire instructions for the premises.

Warning!

Risk for burn injuries on the skin.

2.

Take a little hydraulic oil in a teaspoon and heat the spoon with a cigarette lighter; if there is a crackling sound this proves that it contains water and should be changed.

The hydraulic oil should be filtered when filling, by pouring the oil through the filter.

8.3.1

Oil change

Requisite equipment: • New oil, or purifying equipment for the old.

• A tray to collect the oil in.

• A clamp or plug for the suction pipe.

1

Remove the lower machine housing plate and fold out the machine housing cover.

2.

Check how much oil needs to be filled by checking the oil level (the level differs between different truck variants).

3.

Lower the forks to their lowest position and disconnect the battery.

4.

Place the tray on the floor behind the truck.

ATLET SERVICE MANUAL

Hydraulic oil, changing/draining

Hydraulic system

5.

8.9

Clamp the suction pipe between the pump and tank, release the suction hose from the pump and lead it to the tray, and then release the clamp so that the oil runs out.

Important!

Make sure that the oil does not overflow in the tray. The oil should be taken care of in accordance with national environmental legislation.

Important!

When changing the oil the filters must always be replaced!

6.

Replace the suction pipe, and fill up with new oil through the hydraulic oil filter to the same level as before. If there has been any leakage it will be necessary to fill to a higher level. To obtain the correct oil level all the cylinders should be run to their end positions, and check that the pump does not suck air. Run in the cylinders and check that the oil tank does not overflow.

7.

Wipe up any oil spillage, close the cover, and fit the machine housing plate.

Hydraulic oil, changing/draining

ATLET SERVICE MANUAL

8.10

8.4

Hydraulic system

Air filter, replacing 0

The air filter is located on the hydraulic tank.

1

Unscrew the top on the black filter jar, pos. 1 figure 8.8.

2.

Remove the filter, pos. 29.

3.

Wipe clean the filter jar with a cloth that does not leave fibres.

4.

Insert a new filter and screw on the top.

5 34 32 31 43

4

42 1 29 30

33

28

22

26

pE 62.5

25

24

Figure 8.8 Hydraulic tank

ATLET SERVICE MANUAL

Air filter, replacing

Hydraulic system

8.5

8.11

Filter insert, replacing 0

1

Lower down the forks and disconnect the battery.

2.

Remove the top plastic panel.

3.

Remove the cover, pos. 5, located on the top of the hydraulic oil tank.

4.

Remove the spring on top of the filter insert, lift up the filter insert, pos. 32, and wait until the oil has run off the filter and then lift it out.

5.

Unscrew the wing nut, pos. 4, and pull loose the filter from the rod.

6.

Clean the magnet on the rod, the purpose of which is to capture swarf.

7.

Insert a new filter, and screw tight with the wing nut by hand until it goes in all the way.

8.

Replace the filter insert in the hydraulic oil tank, replace the spring, fit a new O-ring, pos. 33, put the cover on, and fit the screws. Tighten them moderately to avoid damaging the thread.

9.

Close the machine housing cover and fit the plastic panel.

Filter insert, replacing

ATLET SERVICE MANUAL

8.12

8.6

Hydraulic system

Valves, AJN / ASN / ATF 0

The hydraulic system includes several different types of valves, such as lowering brake valve, hose rupture valve and hydraulic valve (overflow valve).

8.6.1

Lowering brake valve, general

The lowering brake valve regulates the lowering speed and is mounted in a valve housing, placed in the lower section of the mast. It controls the lowering speed for the final stroke cylinders. For free lift there is a lowering brake valve in the bottom of the free lift cylinder.

The valve is set at the factory, but may be subsequently adjusted. Check the lowing speed in relation to table 8.1 before repairing or adjusting.

8.6.2

Lowering brake valve, dismantling and assembling

1

Lift the forks so that the inner mast lifts approx. 30 cm. Place a block under the inner mast and carefully lower down so that the mast rests on the block.

Continue lowering until the system is pressure-less. Push out the battery to improve access.

2.

Place protective paper under the truck, release the hose, pos. 17 figure 8.9, from the valve housing and plug it.

3.

Loosen the nipple, pos. 14, in the end of the valve housing, screw in the lowering speed valve, pos. 16, and plug the valve housing, pos. 15.

4.

If a fault is suspected on the valve, it should be checked. There are specific dimensions for the spring length, depending on which cylinder it is to protect.

5.

Adjust the valve, or replace with a new one, and fit it in the valve housing.

6.

Fit the nipple, pos. 14, and connect the hose, pos. 17, push back the battery, and test.

17 14 15 13

14 16

pE 114.1

Figure 8.9 Lowering brake valve

ATLET SERVICE MANUAL

Valves, AJN / ASN / ATF

Hydraulic system

8.6.3

8.13

Setting the lowering brake valve Table 8.1

Machine type

Marking

s mm

v s/m

Q L/min

A 100

SB23C

19

3,5

20,2

A 120, 125, 140 T

SB23C

13,5

2,4

29,7

A 120, 125, 140 TF

SB25C

13

2,4

39,7

A 120, 125, 140 DT

SB25C

15,5

2,4

36,7

A 120, 125, 140 DTF

SB25C

16

2,4

35,3

A 125 TV

SB27C

15

2,0

40,1

A 125 TFV

SB27C

17

2,0

41,8

A 125 DTFV

SB27C

17

2,0

41,8

A Straddle lift

SB09C

7,5

9,6

10

A 160 T

SB25C

13,5

1,8

37

A 160 TV

SB25C

13,5

2,0

37

A 160 TFV

SB27C

16

1,8

45

A 160 DTFV

SB25C

13,5

1,8

37

A 162, 200 T

SB29C

17

2,4

55

A 162, 200 TF

SB29C

19

2,4

49

A 162, 200 DT

SB29C

18

2,4

53

A 162, 200 DTF

SB29C

17

2,4

55

A 200 TV

SB29C

19

2,0

49,5

A 200 TFV

SB29C

18

2,0

55,7

A 200 DTFV

SB29C

15

2,0

63,3

Valves, AJN / ASN / ATF

ATLET SERVICE MANUAL

8.14

Hydraulic system

SM 170.1

S

Figure 8.10 Lowering brake valve

8.6.4

Hose rupture valve, general

Hose rupture valves, the purpose of which is to prevent the forks dropping down out of control if, for example, a hydraulic hose ruptures, are fitted in most of the lift and stabiliser cylinders. They are placed in front of the nipple connected for the supply of hydraulic oil. There is a lowering brake valve in the free lift cylinder.

8.6.5

Hose rupture valve, dismantling and assembling

1

Lower down the forks and relieve the pressure.

2.

Place protective paper under the cylinder to be repaired.

3.

Loosen the pipe or hose that goes to the cylinder, and plug it.

4.

Remove the nipple placed in the cylinder.

5.

Unscrew the hose rupture valve, pos. 6 figure 8.5, that is screwed into the cylinder.

6.

If a fault is suspected, check the length of the spring in relation to the table or data sheet. Adjust, or fit a new valve.

7.

Fit the nipple, connect the pipes, and wipe clean.

8.

Test run.

ATLET SERVICE MANUAL

Valves, AJN / ASN / ATF

Hydraulic system

8.15

6

pF 68.2

Figure 8.11 Hose rupture valve

8.6.6

Setting the hose rupture valve Table 8.2

Machine type

Marking

s mm

Q L/min

A 100 T

LB3C

1,2

50

A 125 TV

LB3C

1,2

50

ATF, A 125 DTFV Free lift

LB3C

2,5

73

ATF, A 125 DTFV Final stroke

LB3C

1,2

50

A 162, 200 TV

LB3C

1,1

47

A 162, 200 TFV, DTFV Free lift

LB3C

3,5

90

A 162, 200 TFV, DTFV Final stroke

LB3C

1,2

50

A 160 T

Does not have hose rupture valve

A 160 TV

LB3C

1,2

50

A 160 TFV Free lift

LB3C

2,5

80

A 160 TFV Final stroke

LB3C

1,2

50

A 160 DTFV Free lift

LB4C

2,0

125

A 160 DTFV Final stroke

LB3C

2,5

80

Valves, AJN / ASN / ATF

ATLET SERVICE MANUAL

8.16

Hydraulic system

SM210-1

Figure 8.12 Hose rupture valve

8.6.7

Hydraulic valve, general

The hydraulic valve does not have any replaceable parts. There is a built-in adjustable overflow valve in the valve.

8.6.8

Hydraulic valve, dismantling and assembling

1

Lower down the forks and relieve the pressure in the hydraulic system.

2.

Switch off the key switch.

3.

Move the lever backwards and forwards a few times.

4.

Remove the plastic panel over the valve.

5.

Place protective paper under the valve and release the electric cables to the microswitch(s).

6.

Loosen all the oil pipes connected to the valve.

7.

Loosen the valve from the truck, and lift it out.

8.

When fitting, first place the valve in the truck but do not tighten until all the oil pipes are connected. Tighten the valve and then the oil pipes.

9.

Adjust the pressure limiting valve to the rated weight in accordance with the machine name-plate.

10. Seal the setting.

ATLET SERVICE MANUAL

Valves, AJN / ASN / ATF

Hydraulic system

8.17

21 20

19

18 2

17 1 16

13 3

10 12

4

11 15 14

5 7 6

8 9

E 110.1

Figure 8.13 Control valve

Valves, AJN / ASN / ATF

ATLET SERVICE MANUAL

8.18

Hydraulic system

E 52.1

Figure 8.14 Control valve

ATLET SERVICE MANUAL

Valves, AJN / ASN / ATF

Hydraulic system

8.7

8.19

Hydraulic motor ASN / ATF 0

8.7.1 1

Dismantling

Lift the forks to their highest position to lower the hydraulic oil level in the tank, thus reducing oil leakage at the pump shaft when the motor is removed.

Warning!

Do not work under the forks.

2.

Disconnect the battery.

3.

Open the machine housing cover and release the cables to the hydraulic motor.

4.

Loosen the four retaining bolts, pos. 15 figure 8.15, that hold the pump to the hydraulic motor.

5.

Loosen and remove the bolts that hold the clamp round the hydraulic motor.

6.

Remove the loosened retaining bolts, pos. 15, loosen the pump from the hydraulic motor, and then lift off the hydraulic motor.

For repair of the hydraulic motor, see Repairing the drive motor, section 5.

Assemble in the reverse order.

Important!

Check that the connector, pos. 12, is turned in the right direction and that the motor and pump journals come at 90° in relation to each other.

Hydraulic motor ASN / ATF

ATLET SERVICE MANUAL

8.20

Hydraulic system

E 33.4

Figure 8.15 Lift motor

ATLET SERVICE MANUAL

Hydraulic motor ASN / ATF

Hydraulic system

8.8

8.21

Hydraulic motor AJN / ATF 0

8.8.1

Dismantling

1

Disconnect the battery.

2.

Open the machine housing cover and release the cables to the motor.

3.

Loosen the two retaining bolts that hold the pump to the motor.

4.

Loosen and remove the bolts that hold the clamp round the motor.

5.

Remove the retaining bolts, and release the pump from the motor.

Assemble in the reverse order.

Important!

Grease in the pump journal before fitting!

8.8.2

Checking the lift motor AJN/STF 0

1

Remove the protective band that sits round the motor, and check the carbon brush wear. Check if there is any oil or other impurities in the motor.

2.

When the carbon brushes, and/or the collector, are so worn that any spring pressing on the brush lies closer to the brush holder than 2 mm, then the carbon brushes and/or the motor armature must be replaced. The minimum diameter of the collector is 48 mm.

3.

If oil has got into the motor it should be cleaned with an alcoholic detergent.

4.

If oil has got onto the carbon brushes they must be replaced.

5.

Check that all connections are tightened.

6.

After replacing the carbon brushes, check that the copper rails inside the motor do no touch anything and cause short-circuiting.

7.

When fitting the protective band, check that it does not touch the connecting cables to the carbon brushes and cause short-circuiting.

When the collector is damaged, it is recommended to replace the complete motor.

See figure 8.16

Hydraulic motor AJN / ATF

ATLET SERVICE MANUAL

8.22

Hydraulic system

38

1

2

37 3

4 23

7 6 8

5

9 10

24

11 12 27

25 26

28

13

29

14

30

15

16

31 40

17 18

19

32

20 33

21 34 35 36

22 39

E 32.3

Figure 8.16 Lift motor

ATLET SERVICE MANUAL

Hydraulic motor AJN / ATF

Hydraulic system

8.9

8.23

Stabiliser cylinders ASN / AJN 0

The stabiliser cylinders have in their upper end a flexible attachment, the purpose of which is to compensate for minor irregularities in the floor. For certain markets there is also a hose rupture valve mounted in the cylinder.

SM 077.1

Figure 8.17 Stabiliser cylinder

8.9.1

Dismantling and assembling

1

Run out the stabilisers, disconnect the battery, and read off the pressure in the pipes by moving the control backwards and forwards.

2.

Release the hoses and plug them.

3.

Remove the lower bolt that goes through the piston rod end.

Stabiliser cylinders ASN / AJN

ATLET SERVICE MANUAL

8.24

Hydraulic system

4.

Loosen the upper cylinder bolt, and lift out the cylinder.

E 59.3

Figure 8.18 Stabiliser cylinder, detailed drawing

8.9.2

Spring unit, dismantling and assembling

1

Support the upper cylinder bolt, pos. 2, in a vice and loosen the lock nuts, pos. 3, figure 8.18. Support the spring holder, pos. 6, with a spanner.

2.

Release the upper cylinder bolt from the vice and carefully support the top end of the cylinder body.

Important!

There is a risk of deforming the cylinder.

3.

Check how far the cylinder bolt is screwed in, unscrew it, remove the nut, pos. 5, and lift out the spring holder, pos. 6, with the spring, pos. 7.

4.

Remove the stop screw and nut, pos. 9 and 10, before fitting. Lubricate the spring and spring holder, pos. 6 and 7, with grease and fit in the reverse order. Screw tight the stop screw, pos. 8, and lock with the nut, pos. 10.

ATLET SERVICE MANUAL

Stabiliser cylinders ASN / AJN

Hydraulic system

8.9.3 1

8.25

Dismantling and assembling, gaskets

Carefully support the cylinder in the end the spring device is located.

Important!

There is a risk of deforming the cylinder.

2.

Unscrew the piston rod guide, pos. 23 figure 8.18, and pull the piston rod out of the cylinder tube.

3.

Support the piston rod in the vice in the end that normally sits in the support arm; use protective jaws on the vice.

4.

Loosen the nut, pos. 14, and remove the gasket holder, pos. 16, with the piston seals.

Important!

Before fitting, all seals should be lubricated with hydraulic oil.

5.

Assemble in the reverse order.

Stabiliser cylinders ASN / AJN

ATLET SERVICE MANUAL

8.26

8.10

Hydraulic system

Hydraulic diagram 0

Table 8.3 Description

Machine type

Hydraulic diagram

A / ATF

Hydraulic diagram

A / ATF

From: W9148

085243

Hydraulic diagram

A

From: W9148

085254

Hydraulic diagram

A

From: W9148

085255

ATLET SERVICE MANUAL

Reference

Document code 085046

Hydraulic diagram

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Lift cylinders 9.1 Introduction................................................................................................................... 9.1 9.2 Free lift cylinder TFV / DTFV........................................................................................ 9.2 9.2.1 Dismantling and assembling .........................................................................................9.2 9.2.2 Dismantling and assembling to: W-9638 ......................................................................9.2 9.2.3 Dismantling and assembling from: W-9639 .................................................................9.4 9.3 Lift cylinder TV/ TFV/ DTFV (not 160) ........................................................................ 9.6 9.3.1 Dismantling and assembling .........................................................................................9.6 9.3.2 Dismantling and assembling to: W-9638 ......................................................................9.7 9.3.3 Dismantling and assembling from: W-9638 .................................................................9.8 9.4 Lift cylinder TV/ TFV/ DTFV (160) ............................................................................. 9.10 9.4.1 Dismantling and assembling .......................................................................................9.10 9.4.2 Dismantling and assembling .......................................................................................9.11 9.5 Lift cylinder 100 DT / 125 DT to: A -11508 ................................................................ 9.13 9.5.1 Dismantling and assembling .......................................................................................9.13 9.5.2 Dismantling and assembling .......................................................................................9.14 9.6 Lift cylinder 100 DT / 125 DT from: A -11509............................................................ 9.16 9.6.1 Dismantling and assembling .......................................................................................9.16 9.6.2 Dismantling and assembling .......................................................................................9.17 9.7 Lift cylinder 100 T / 125 T........................................................................................... 9.19 9.7.1 Dismantling and assembling .......................................................................................9.19 9.7.2 Dismantling and assembling .......................................................................................9.20 9.8 Lift cylinder 160 T ....................................................................................................... 9.21 9.8.1 Dismantling and assembling .......................................................................................9.21 9.8.2 Dismantling and assembling .......................................................................................9.22

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

9.9 Bleeding the cylinders ............................................................................................... 9.23 9.9.1 Bleeding TV/ TFV/ DTFV to: W-9638 ...................................................................... 9.23 9.9.2 Bleeding models from: W-9639 ................................................................................. 9.23

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Lift cylinders

9.1

Edition 2001A

9 Lift cylinders 9.1

Introduction 0

The lift cylinders consist of single-acting hydraulic cylinders, where a hydraulic oil is pumped into the cylinder and presses out the piston rod.

When the driver activates the lowering function the cylinders are pressed together through a control valve releasing oil out from the cylinders. They are then pushed together by the weight of the forks, at the same time as the oil returns to the hydraulic tank.

As opposed to the lift cylinders, the side stabiliser cylinders are double-acting.

This implies that a hydraulic oil also acts in the opposite direction and pushes the cylinder together.

SM_A_09_e_2001a.fm

Introduction

ATLET SERVICE MANUAL

9.2

9.2

Lift cylinders

Free lift cylinder TFV / DTFV 0

9.2.1

Dismantling and assembling

1

Lift up the forks and remove the stop screw located at the bottom of one side of the inner mast (not 160).

2.

Remove the retaining screw that holds the lower end of the cylinder.

3.

Lower down the forks, e.g. on a pallet, so that the chain slackens. Remove the chain pin that goes through the chain bolt on the cylinder, and place the chain over the back of the fork carriage.

4.

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

5.

Lower down the control lever so that all the cylinders are pushed together completely.

6.

Loosen the bolts that hold the clamp at the top end of the cylinder, without removing it.

7.

Loosen and disconnect the oil pipe.

8.

Remove the clamp, and lift out the cylinder.

9.

Plug the oil pipe.

10. Assemble in the reverse order.

9.2.2 1

Dismantling and assembling to: W-9638 Support the lower end of the cylinder in a vice.

Important!

Risk of deformation, use moderate tensioning.

2.

Remove the lock ring, pos. 25 figure 9.1, and remove the yoke, pos. 12.

3.

Place a container for oil spillage under the cylinder.

4.

Remove the top nut, pos. 3, with a suitable tool and take it off the piston rod.

5.

Take out the piston rod.

6.

Remove the seals, pos. 11, and guide rings, pos. 10, on the piston. Use a thin tool that will not scratch.

7.

Remove the seal, pos. 7, and scraper, pos. 6, from the top nut and O-ring, pos. 8.

8.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

ATLET SERVICE MANUAL

Free lift cylinder TFV / DTFV

Lift cylinders

9.

9.3

Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

33

2

34 35 36 37

F 29.2

Figure 9.1 Free lift cylinder to: W-9638

Free lift cylinder TFV / DTFV

ATLET SERVICE MANUAL

9.4

Lift cylinders

9.2.3 1

Dismantling and assembling from: W-9639 Support the lower end of the cylinder in a vice.

Important!

Risk of deformation, use moderate tensioning.

2.

Remove the lock ring, pos. 6 figure 9.2, and remove the yoke, pos. 11.

3.

Place a container for oil spillage under the cylinder.

4.

Remove the top nut, pos. 14, with a suitable tool and take it off the piston rod.

5.

Take out the piston rod.

6.

Remove the seals, pos. 19, and guide rings, pos. 18, on the piston. Use a thin tool that will not scratch.

7.

Remove the seal, pos. 13, and scraper, pos. 12, from the top nut and O-ring, pos. 15.

8.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

9.

Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

ATLET SERVICE MANUAL

Free lift cylinder TFV / DTFV

Lift cylinders

9.5

25 21

21

22

1 3

2

23

4 5

24 5

6 11

X X X X X

9 32

9

10

26 27

A 17

8

28 29 20

12

13

14 34 35 33

15

16

18

30

19

F 71.1

31

Figure 9.2 Free lift cylinder from: W-9639

Free lift cylinder TFV / DTFV

ATLET SERVICE MANUAL

9.6

9.3

Lift cylinders

Lift cylinder TV/ TFV/ DTFV (not 160) 0

9.3.1

Dismantling and assembling

1

Lift the forks until the inner mast is raised approx. 20 mm, place wooden blocks under the inner mast, and lower it down onto the blocks.

2.

Loosen the upper retaining screws, pos. 20 figure 9.3.

3.

Lower down the cylinder to the compressed position and loosen the retaining screw, pos. 47 figure 9.4.

4.

Loosen, disconnect, and plug the oil pipe.

5.

Release the clamp, pos. 34 figure 9.4, located outside the top end of the cylinder, and move to one side.

6.

Lift out the cylinder.

7.

Assemble in the reverse order.

F 28.2

Figure 9.3 Lift cylinder to: W-9638

ATLET SERVICE MANUAL

Lift cylinder TV/ TFV/ DTFV (not 160)

Lift cylinders

9.7

35 52 41

42

44

43

45 36 37 1

51

38 39

34 33

40 10 4 2

3

9 49

8

50

7 6

5

46

pC 87.1

47

48

Figure 9.4 Mast example

9.3.2

Dismantling and assembling to: W-9638

1

Note how far the adjusting screw, pos. 15 figure 9.3, is screwed into the piston rod end (required when fitting).

2.

Unscrew the adjusting screw, pos. 15.

3.

Support the lower end of the cylinder in a vice.

Important!

Risk of deformation, use moderate tensioning.

4.

Place a container for oil spillage under the cylinder.

5.

Loosen the top nut, pos. 3, and remove it, and take out the piston rod, pos. 1.

Lift cylinder TV/ TFV/ DTFV (not 160)

ATLET SERVICE MANUAL

9.8

Lift cylinders

6.

Remove the sealing rings and guide rings, pos. 7, 8, 9 and 10, from the top nut.

7.

Remove the guide rings, pos. 6, from the piston rod.

8.

Remove the piston, pos. 5.

9.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

10. Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

9.3.3

Dismantling and assembling from: W-9638

1

Note how far the adjusting screw, pos. 8 figure 9.5, is screwed into the piston rod end (required when fitting).

2.

Unscrew the adjusting screw, pos. 8.

3.

Support the lower end of the cylinder in a vice.

Important!

Risk of deformation, use moderate tensioning.

4.

Place a container for oil spillage under the cylinder.

5.

Loosen the top nut, pos. 13, and remove it, and take out the piston rod, pos. 5.

6.

Remove the sealing rings and scraper, pos. 2, 6 and 7, from the top nut.

7.

Remove the guide rings, pos. 3, from the piston rod.

8.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

9.

Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

ATLET SERVICE MANUAL

Lift cylinder TV/ TFV/ DTFV (not 160)

Lift cylinders

9.9

12 2 11 10

A

X X X X X

8

5 7

6 1

13

14

4

3

15

F 75.1

Figure 9.5 Lift cylinder from: W-9639

Lift cylinder TV/ TFV/ DTFV (not 160)

ATLET SERVICE MANUAL

9.10

9.4

Lift cylinders

Lift cylinder TV/ TFV/ DTFV (160) 0

9.4.1

Dismantling and assembling

1

Lift the forks until the inner mast is raised approx. 20 mm, place wooden blocks under the inner mast, and lower it down onto the blocks.

2.

Loosen the upper retaining screws, pos. 12 figure 9.6.

3.

Lower down the cylinder to compressed position.

4.

Loosen, disconnect, and plug the oil pipe.

5.

Remove the retaining screw, pos. 13 figure 9.7.

6.

Lift out the cylinder.

7.

Assemble in the reverse order.

12 11 10

A

X X X X X

8

7 16 6

5

1

4

13

14

2

3

15

F 151.2

Figure 9.6 Lift cylinder for 160 mast

ATLET SERVICE MANUAL

Lift cylinder TV/ TFV/ DTFV (160)

Lift cylinders

9.11

4 5

45

47

6 7

46

2 44

48 41 43

49 52 51

13 20 21 22

45 14

50

23 47

42

24

52 10 12

11

9 3

9

10 11 14 15

16 17

1

27 28 35

30 9 33

31 34 27 1

28

C 160.1

40

39

38

Figure 9.7 160 mast (DTFV)

9.4.2

Dismantling and assembling

1

Note how far the adjusting screw, pos. 8 figure 9.6, is screwed into the piston rod end (required when fitting).

2.

Unscrew the adjusting screw, pos. 8.

3.

Support the lower end of the cylinder in a vice.

Important!

Risk of deformation, use moderate tensioning.

4.

Place a container for oil spillage under the cylinder.

5.

Loosen the top nut, pos. 13, and remove it, and take out the piston rod, pos. 16.

Lift cylinder TV/ TFV/ DTFV (160)

ATLET SERVICE MANUAL

9.12

Lift cylinders

6.

Remove the sealing rings and guide rings, pos. 4, 5, 6 and 7, from the top nut.

7.

Remove the guide rings, pos. 3, from the piston rod.

8.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

9.

Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

ATLET SERVICE MANUAL

Lift cylinder TV/ TFV/ DTFV (160)

Lift cylinders

9.5

9.13

Lift cylinder 100 DT / 125 DT to: A -11508 0

9.5.1

Dismantling and assembling

1

Lift up the forks and remove the stop screw located at the bottom of one side of the inner mast.

2.

Lower down the forks, e.g. on a pallet, so that the chain slackens. Remove the split pin bolt, pos. 31 figure 9.8, that sits in the top end of the cylinder.

(New version, pos. 22 figure 9.5)

3.

Remove the chain and place it over the back of the fork carriage.

4.

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

5.

Secure the cylinder so that it cannot drop out of the mast! Remove the lower retaining screw, pos. 57 figure 9.9.

6.

Remove the lock ring, pos. 26 figure 9.8. (New version, pos. 8 figure 9.5)

7.

Place a wooden block under the inner mast, 10-15 cm thick, and carefully lower the inner mast until it rests on the block.

8.

Lower carefully so that the piston rod comes out of the yoke, pos. 27 figure 9.4. (New version, pos. 9 figure 9.5)

9.

When the piston rod is fully pushed in, remove the oil pipe and return pipe, and plug them. Tilt forward the cylinder and lift it out.

10. Assemble in the reverse order.

Lift cylinder 100 DT / 125 DT to: A -11508

ATLET SERVICE MANUAL

9.14

Lift cylinders

F 42.2

Figure 9.8 Lift cylinder to: A - 11508

9.5.2

Dismantling and assembling

1

Place the cylinder on a bench.

2.

Loosen and remove the top nut, pos. 15 figure 9.8, with a hook spanner.

3.

Pull out the piston rod, pos. 20, and place it carefully on the bench to avoid damaging it.

4.

Bend away the locking washer, pos. 7, remove the nut, pos. 8, and remove the parts, pos. 2, 3, 4, 5, and 6.

5.

Remove the O-ring, pos. 14, and scraper, pos. 13.

6.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

ATLET SERVICE MANUAL

Lift cylinder 100 DT / 125 DT to: A -11508

Lift cylinders

7.

9.15

Assemble in the reverse order. Replace the locking washer, pos. 7 figure 9.8, if has been removed. Oil in all parts with hydraulic oil before fitting.

56 pC 5 3.3

57

Figure 9.9 Mast example

Lift cylinder 100 DT / 125 DT to: A -11508

ATLET SERVICE MANUAL

9.16

Lift cylinders

9.6

Lift cylinder 100 DT / 125 DT from: A -11509 0

9.6.1

Dismantling and assembling

1

Lift up the forks and remove the stop screw located at the bottom of one side of the inner mast.

2.

Lower down the forks, e.g. on a pallet, so that the chain slackens. Remove the split pin bolt, pos. 22 figure 9.10, that sits in the top end of the cylinder.

3.

Remove the chain and place it over the back of the fork carriage.

4.

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

5.

Secure the cylinder so that it cannot drop out of the mast! Remove the lower retaining screw, pos. 57 figure 9.9.

6.

Remove the lock ring, pos. 8 figure 9.10.

7.

Place a wooden block under the inner mast, 10-15 cm thick, and carefully lower the inner mast until it rests on the block.

8.

Lower carefully so that the piston rod comes out the yoke, pos. 9 figure 9.10.

9.

When the piston rod is fully pushed in, remove the oil pipe and return pipe, and plug them. Tilt forward the cylinder and lift it out.

10. Assemble in the reverse order.

ATLET SERVICE MANUAL

Lift cylinder 100 DT / 125 DT from: A -11509

Lift cylinders

9.17

7 6 5 4 8

2 1 31 9 10 11 3 22 18 12

21

13

23

19 25

14 15 33 16 34 24 20

17

27 26

F 67.3

Figure 9.10 Lift cylinder from: A - 11509

9.6.2

Dismantling and assembling

1

Place the cylinder on a bench.

2.

Loosen and remove the top nut, pos. 13 figure 9.10, with a hook spanner.

3.

Pull out the piston rod, pos. 17, and place it carefully on the bench to avoid damaging it.

Lift cylinder 100 DT / 125 DT from: A -11509

ATLET SERVICE MANUAL

9.18

Lift cylinders

4.

Remove the O-ring, pos. 18, and scraper, pos. 19.

5.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

6.

Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

ATLET SERVICE MANUAL

Lift cylinder 100 DT / 125 DT from: A -11509

Lift cylinders

9.7

9.19

Lift cylinder 100 T / 125 T 0

9.7.1

Dismantling and assembling

1

Lift up the forks and remove the stop screw located at the bottom of one side of the inner mast.

2.

Lower down the forks, e.g. on a pallet, so that the chain slackens. Remove the split pin bolts, pos. 2 figure 9.7, that sit in the top end of the cylinder.

3.

Remove the chain and place it over the back of the fork carriage.

4.

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

5.

Place a wooden block under the inner mast, 10-15 cm thick, and carefully lower the inner mast until it rests on the block.

6.

Secure the cylinder so that it cannot drop out of the mast! Tap out the retaining pin, pos. 15 figure 9.11, and remove the lower retaining screw, pos.

42 figure 9.12.

7.

Lower carefully so that the piston rod comes out the yoke, pos. 16 figure 9.11.

8.

When the piston rod is fully pushed in, remove the oil pipe and return pipe, tilt forward the cylinder, and lift it out.

9.

Assemble in the reverse order.

16 17 18 19 20

9

21 15 22

23

1 14 2 13 4 5 2 12 3

11

10

8

6

7

F 68.2

Figure 9.11 Lift cylinder

Lift cylinder 100 T / 125 T

ATLET SERVICE MANUAL

9.20

Lift cylinders

13 14 15

1

41 42 pC 97.1

Figure 9.12 Mast example

9.7.2

Dismantling and assembling

1

Place the cylinder on a bench with the chain attachment facing down.

2.

Loosen and remove the top nut, pos. 12 figure 9.11, with a hook spanner.

3.

Pull out the piston rod, pos. 9, and place it carefully on the bench to avoid damaging it.

4.

Remove the parts, pos. 7, 8, 10, 11, 13 and 14.

5.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

6.

Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

ATLET SERVICE MANUAL

Lift cylinder 100 T / 125 T

Lift cylinders

9.8

9.21

Lift cylinder 160 T 0

9.8.1

Dismantling and assembling

1

Lower down the forks, e.g. on a pallet, so that the chain slackens. Remove the split pin bolt, pos. 32 figure 9.13, that sits in the top end of the cylinder.

2.

Remove the chain and place it over the back of the fork carriage.

3.

Release the fork carriage from the mast by lifting up the inner mast with the hydraulic pump. Reverse the truck away.

4.

Place a wooden block under the inner mast, 10-15 cm thick, and carefully lower the inner mast until it rests on the block.

5.

Secure the cylinder so that it cannot drop out of the mast! Remove the locking washer, pos. 9 figure 9.13, and remove the lower retaining screw, pos. 42 figure 9.12.

6.

Lower carefully so that the piston rod comes out of the yoke, pos. 14 figure 9.13.

7.

When the piston rod is fully pushed in, remove the oil pipe and return pipe, tilt forward the cylinder, and lift it out.

8.

Assemble in the reverse order.

Lift cylinder 160 T

ATLET SERVICE MANUAL

9.22

Lift cylinders

30

19 18 16

31

17

32

14 15 33

34

9 21

20 8

22

7 44 X X X X X

45

6 46

A

47 11

36 37

10

1

39

5

38 4

48

3

2

F 150.2

Figure 9.13 Lift cylinder

9.8.2

Dismantling and assembling

1

Place the cylinder on a bench with the chain attachment facing down.

2.

Loosen and remove the top nut, pos. 10 figure 9.13, with a hook spanner.

3.

Pull out the piston rod, pos. 11, and place it carefully on the bench to avoid damaging it.

4.

Remove the parts, pos. 2, 3, 4, 5, 6 and 7.

5.

Clean all parts and check for damage. Replace if necessary.

Note!

Always use original spare parts for maximum safety and service-life.

6.

Assemble in the reverse order. Oil in all parts with hydraulic oil before fitting.

ATLET SERVICE MANUAL

Lift cylinder 160 T

Lift cylinders

9.9

9.23

Bleeding the cylinders 0

Warning!

When bleeding, the air screw must be opened no more than approx. a half turn.

If the air screw is opened completely the oil will spurt out and the forks crash uncontrollably to bottom position. The hose rupture valves do not function in this phase.

9.9.1

Bleeding TV/ TFV/ DTFV to: W-9638

1

Carefully loosen the air screw, pos. 11 figure 9.3

2.

Check that there is sufficient oil in the hydraulic tank and that the pump does not suck air. Run carefully with the pump in intervals, and allow the air to hiss out.

3.

When oil comes out without air bubbles, close the air screw. Bleed the outer cylinders alternately.

4.

Adjust the oil level in the hydraulic tank.

5.

Repeatedly lift from bottom to top position.

6.

Check that the forks do not give, if so repeat the bleeding one or more times.

9.9.2

Bleeding models from: W-9639

Cylinders from W-9639 do not have air screws. They are bled by running the cylinder repeatedly between its end positions.

Important!

Check the oil level regularly.

Bleeding the cylinders

ATLET SERVICE MANUAL

9.24

ATLET SERVICE MANUAL

Lift cylinders

Bleeding the cylinders

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Electrical system 10.1 Safety procedures .................................................................................................... 10.1 10.2 Battery maintenance ................................................................................................ 10.2 10.2.1 Truck driver’s responsibility .....................................................................................10.2 10.2.2 Foreman’s responsibility ...........................................................................................10.2 10.2.3 Checking of the battery fluid ....................................................................................10.2 10.3 Drive motor ............................................................................................................... 10.3 10.3.1 Dismantling and assembling .....................................................................................10.3 10.3.2 Replacing the drive motor cable ...............................................................................10.3 10.4 Fork drive motor, ATF truck .................................................................................... 10.5 10.4.1 Dismantling and assembling .....................................................................................10.5 10.4.2 Replacing the carbon brushes ...................................................................................10.6 10.4.3 Replacing the coupling between motor and gear. .....................................................10.7 10.4.4 Electric cable to fork drive motor, replacing ............................................................10.7 10.5 Speed controller ....................................................................................................... 10.8 10.5.1 Dismantling, assembling the speed controller ..........................................................10.8 10.5.2 Adjusting the speed controller ..................................................................................10.8 10.5.3 Checking the microswitches ...................................................................................10.10

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

10.6 Sigma Transistor - System TR 250 CS ................................................................. 10.11 10.6.1 Regulation ............................................................................................................... 10.11 10.6.2 Throttle ................................................................................................................... 10.11 10.6.3 Adjustment of the potentiometers P1, P2, P3, and P4 ............................................ 10.12 10.6.4 Safety switch function to avoid crushing injuries .................................................. 10.12 10.6.5 Description of display ............................................................................................. 10.13 10.6.6 Failsafe function .................................................................................................... 10.13 10.6.7 Other safety functions ............................................................................................. 10.14 10.6.8 Test of safety functions ........................................................................................... 10.14 10.6.9 Connections and voltage values ............................................................................. 10.15 10.6.10 Trouble shooting SIGMA 250 TR ........................................................................ 10.17 10.7 Curtis 1207 .............................................................................................................. 10.21 10.7.1 Hand terminal ......................................................................................................... 10.22 10.7.2 Special Program ...................................................................................................... 10.23 10.7.3 Special Diagnostic .................................................................................................. 10.23 10.7.4 Programming .......................................................................................................... 10.23 10.7.5 Adjustment instructions .......................................................................................... 10.23 10.7.6 Available adjustment parameters ............................................................................ 10.26 10.7.7 Adjusting values ..................................................................................................... 10.27 10.7.8 Function and installation check Curtis ................................................................... 10.28 10.7.9 Trouble shooting by means of LED ....................................................................... 10.30 10.7.10 Trouble shooting by means of Hand terminal ...................................................... 10.31 10.7.11 Trouble shooting by means of Test menu ............................................................ 10.32 10.7.12 Specifications ........................................................................................................ 10.33 10.8 Side stabilisers ....................................................................................................... 10.34 10.8.1 Adjusting ................................................................................................................ 10.35 10.9 Wiring diagram ....................................................................................................... 10.36

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Electrical system

10.1

Edition 2001A

10 Electrical system 10.1

Safety procedures 0

• During all work in the truck’s electrical system, or in its immediate vicinity, rings, watches and other metal objects must be removed since the battery capacity is such that a short circuit over such an object can result in very serious burn injuries.

• Work with electrical vehicles can result in personal injury. All testing, trouble shooting and adjusting must be carried out by authorised personnel. The drive wheel should run free of the floor and be able to rotate freely during work.

• The drive regulator has a multiple safety system.

• When replacing or repairing the regulator, or removing cables, the battery should always be disconnected.

• Since the trucks are not fitted with series contactors to the drive regulator, it is important to ensure that the correct polarity is connected to its main supply via the battery plug.

SM_A_10_e_2001a.fm

Safety procedures

ATLET SERVICE MANUAL

10.2

10.2

Electrical system

Battery maintenance 0

10.2.1

Truck driver’s responsibility

Every day the truck driver is responsible to ensure that: • Charging of the battery is carried out in accordance with the recommendations of the battery manufacturer.

• The acid weight is checked.

• The other parts or the battery and charger function (see separate maintenance instructions).

• The battery is properly locked.

Note!

The acid level rises during charging.

10.2.2

Foreman’s responsibility

Every 250 working hours the foreman is responsible to ensure that: • The battery is checked with regard to its attachment, cleanliness, cracking, and the acid level.

• The battery’s specific acid weight is measured.

• The function of the charger is tested.

10.2.3

Checking of the battery fluid

Warning!

Protective equipment must be used.

Check that: • The fluid level covers the battery’s mechanical parts in all the cells.

• The specific acid weight lies between 1.28 – 1.30 at approx. 30° C when the battery is fully charged.

ATLET SERVICE MANUAL

Battery maintenance

Electrical system

10.3

10.3

Drive motor 0

10.3.1

Dismantling and assembling

1

Remove the bottom cover.

2.

Lift up the truck so that the drive wheel is lifted off the floor, and secure with blocks.

3.

Turn the steering wheel until the motor cable becomes accessible, check the marking, and remove it.

4.

Turn the steering wheel in the opposite direction so that the three retaining bolts become accessible, and remove them.

5.

Turn back the steering wheel so that the brake device can be seen. Loosen the retaining screws to the brake, hold the drive motor up while the brake device is dismantled, and then move it out of the way and lift out the motor.

6.

If it is an electric brake it is only necessary to release the cables, not remove the brake.

10.3.2

Replacing the drive motor cable

Dismantling 1

Lift off the machine housing cover.

2.

Dismantle the bottom cover.

3.

Note the cable connections.

4.

Note how the cable is clamped.

5.

Release the cable from the drive motor.

6.

Turn slightly to the right and remove all the cable clips and cable ties.

7.

Loosen the cable connections at the electrical system, and pull it out completely.

Assembly

Drive motor

1

Strip and bend the new cable to resemble the old one.

2.

Insert the new cable and connect the ends.

3.

Clamp it secure and fit the cable ties in the same way as the old cable was secured.

4.

Test turn, and check that it does not catch anywhere.

5.

Test drive the truck, and check that it does not catch anywhere.

6.

Fit the covers.

ATLET SERVICE MANUAL

10.4

Electrical system

Tip Tie a piece of string to the cable’s motor end before pulling it out, then tie the string to the new cable’s motor end and use the string to pull in the new cable through the drive unit plate and past the drive motor. The new cable will then have the same cable routing as the old one.

ATLET SERVICE MANUAL

Drive motor

Electrical system

10.4

10.5

Fork drive motor, ATF truck 0

10.4.1

Dismantling and assembling

1

Release the cable bracket and the cover over the motor, and lift them off.

2.

Note the connection of the electric cables, and release them.

3.

Loosen the bolts, pos. 16 figure 10.1.

4.

Lift the motor straight up.

Fork drive motor, ATF truck

ATLET SERVICE MANUAL

10.6

Electrical system

1 2 1 5 4

3 6

7

8

9

8 10 12 13 11 14

15 16 G 56.2

Figure 10.1 Fork drive motor

10.4.2

Replacing the carbon brushes

Important!

There are powerful magnets in the motor; make sure that swarf does not get into the motor.

1

Remove the bolt, pos. 1 figure 10.1.

ATLET SERVICE MANUAL

Fork drive motor, ATF truck

Electrical system

10.7

2.

Carefully lift the cover, pos. 3, straight up. Support the carbon brushes when they release contact with the collector.

3.

Blow clean with compressed air.

4.

Fit new carbon brushes in the brush holder, hold them in position with your thumbs, and then insert the end in its position.

5.

Fit the cables, the cover, and the bracket.

10.4.3

Replacing the coupling between motor and gear.

1

Dismantle the motor, see section 10.4.1 “Dismantling and assembling”.

2.

Release the coupling by unscrewing the stop screw, pos. 12 figure 10.1, and pull off the coupling.

3.

Push on a new one and tighten it with the stop screw.

4.

Loosen and pull off the coupling half located in the gear, and fit a new one.

5.

Fit the motor, connect the cables, and test drive.

10.4.4

Electric cable to fork drive motor, replacing

1

Lift the forks approx. one metre above the floor.

2.

Release the bracket holding the electric cable at the motor.

3.

Remove the cover over the drive motor end, where the electric cable goes in.

4.

Remove the panel over the component box, including all the clips holding the cable.

5.

Check the markings and positioning of the electric cables.

6.

Release the cable and pull it out.

7.

Move the springs over to the new cable, put it in place, and connect it.

8.

Fit the cover and bracket over the drive motor.

9.

Clamp the cable secure, lift the forks a number of times, and check that it is not trapped, catches, or rubs against something.

10. Fit the panels.

Fork drive motor, ATF truck

ATLET SERVICE MANUAL

10.8

10.5

Electrical system

Speed controller 0

The speed controller controls the drive direction of the truck and its speed. The speed controller is provided with a number of microswitches, which provide signals on the drive direction and regulate the control current to the directional contactors. There is a potentiometer that regulates the driving speed of the truck, i.e. the modulation from the transistor drive system. The potentiometer should be supplied with a stabilised voltage in order to give the correct signal voltage to the transistor system.

Note!

To ensure that the truck moves in satisfactory and safe way the components in the speed controller must be correctly fitted and adjusted.

10.5.1

Dismantling, assembling the speed controller

1

Remove the lever knobs to the hydraulic levers.

2.

Dismantle the panel over the speed controller and the hydraulic valve.

3.

Loosen the speed controller’s four retaining screws, lift forward the speed controller, and separate the cable at the connector.

4.

Assemble in the reverse order. After assembling, check that the speed controller’s control handle does not go against the plastic panel when fully turned in both directions.

10.5.2

Adjusting the speed controller

Starting point for measuring: • The speed controller must not be connected to the drive regulator.

• The control lever should be in neutral!

• Use a measuring instrument with an Ohm scale and a measuring range adapted to the required reading.

1

Grease the links and lubricate the potentiometer shaft moderately.

2.

Adjust the bell crank, pos. 1 figure 10.2, with the screws, pos. 2, so that it turns an equal distance regardless of whether the speed controller is moved backwards or forwards.

3.

Adjust the potentiometer shaft by turning the shaft, pos. 4.

4.

Measure between the black and white cable, and search for the max value.

5.

Adjust by turning the shaft, pos. 4, until the max value increases, and then lock the shaft.

6.

Now check that when the speed controller is fully turned the value is approx.

25-60 Ohm in both directions.

7.

Measure between the green and white cable with speed controller in neutral; the value here should be 25-60 Ohm

ATLET SERVICE MANUAL

Speed controller

Electrical system

10.9

8.

Measure between the green and white cable with the speed controller fully turned in both directions; the value should rise to the max value.

9.

Adjust the distance of the microswitches to the cam curve by pulling the speed controller backwards and pressing the switches to the cam curve, then releasing them 0.5 mm, and locking them with the screw, pos. 5.

10. Adjust the cam curve’s neutral position by turning it so that it actuates the microswitches during equally long movements of the speed controller in both directions.

11. Check that everything runs smoothly and does not jam.

12. Connect the speed controller and test drive the truck. Check also the current to the drive motor with a clip-on ammeter. See also section 10.6.3, Adjusting the motor current.

13. If the truck has a Curtis drive regulator, the potentiometer can be checked by means of the Hand terminal, see section 10.7.1.

3 2

1

4

6

Black White Green SM 079.1e

5

Figure 10.2 Speed controller

Speed controller

ATLET SERVICE MANUAL

10.10

Electrical system

10.5.3

Checking the microswitches

A microswitch can be checked in two different ways, either by measuring the resistance or by measuring it connected in the system and supplied with voltage. If the truck has a Curtis drive regulator, the microswitches can be checked by means of the Hand terminal, see section 10.7.1.

We recommend measuring the switch connected in the system and supplied with voltage.

Starting point: Battery plug connected and the key switch on.

1

Lift up the drive wheel and secure the truck with blocks.

2.

Connect a voltmeter over the terminals to be checked.

3.

Press down the foot switch.

4.

Read off the value; it should be approx. battery plus.

5.

Actuate the switch and read of the value; it should be less than 0.1 volt.

The switch should be replaced if it is higher.

ATLET SERVICE MANUAL

Speed controller

Electrical system

10.6

10.11

Sigma Transistor - System TR 250 CS 0

G 76.2

Figure 10.3 SIGMA TR 250 CS

10.6.1

Regulation

During the braking phase the current is the limiting factor. This gives a variable braking torque during reverse braking. The braking power is regulated with the throttle.

During acceleration the regulation is voltage controlled, with the current limit as the limiting factor. This gives the truck excellent creep driving characteristics.

10.6.2

Throttle

In the speed controller there is a 5 k potentiometer, which is connected to the logic card’s pins 7T, 9T and 15T. Pin 7T has a stabilised 5 V voltage out from the logic card.

Pin 15T has B-

Sigma Transistor - System TR 250 CS

ATLET SERVICE MANUAL

10.12

Electrical system

With the described connection a controllable voltage is given (0-5V) to pin 9T, where 5V gives 100% modulation from the drive regulator on the assumption that the directional contactor is energised.

10.6.3

Adjustment of the potentiometers P1, P2, P3, and P4

When adjusting the motor current it is important to measure at the correct point. The measurement should be made over a cable to the drive motor.

Connect a clip-on ammeter over the drive motor cable connected on A 2.

Place the truck with the forks against a wall and actuate the speed controller to max; read off the ammeter and then release the speed controller. If necessary adjust the trimming potentiometer P 1 (applies to Sigma).

Read off the value and check.

Important!

Each reading must not be longer than 10 seconds.

P1. Max current limit The max current limit is adjusted with potentiometer P1. Clockwise gives a reduced, and anticlockwise gives an increased current value. To adjust P1 the speed controller should not be actuated. I.e., first adjust P1, and then check the max current value achieved. Repeat the procedure until the required current value is achieved.

Table 10.1 Adjusting the current limit Max current limit

225 A

P2. Acceleration The acceleration is adjusted with P2. Clockwise gives increased, and anticlockwise gives decreased acceleration. The longest time is 0.4 s, and the highest is 1.7 s. The acceleration also depends on the throttle signal. A higher throttle signal gives more rapid acceleration.

P3. No function P4. No function

10.6.4

Safety switch function to avoid crushing injuries

This safety switch function is not normally used.

ATLET SERVICE MANUAL

Sigma Transistor - System TR 250 CS

Electrical system

10.6.5

10.13

Description of display

During operation the display shows different numbers or letters. These have the following meanings: Table 10.2 Display description 0

Voltage is on. All registers and time circuits are reset and the parameters of the main transistors are being checked.

2

Incorrect sequence during operation of directional signal. I.e., input 1A, 2A, or both, have been actuated during operation of key switch. For the system to permit pulsing of the main transistor, both inputs must be inactivated by means of the speed controller.

3

Neutral setting. The system has checked that all parameters are in the starting position, and are ready to be used.

4

The directional contactor is in, and the systems modulation lies between 0-25%.

5

Directional in, modulation 25-50%.

6

Directional in, modulation 50-75%.

7

Directional in, modulation 75-99%.

-

Directional in, modulation 100%.

8

The motor is reverse braked: the controller is in the brake phase and is now currentcontrolled. The braking force is determined with the throttle.

A

Both indicating paths for forward/reverse are set low simultaneously (1T, 2T). The main transistors are not permitted to supply current to the drive motor.

C

The current in neutral position is too high. The signal from the current measuring circuit must lie below a certain value, which is measured during status 3.

F

The main transistor was defective when the control voltage was switched on. The system is passive, and remains in this state until the fault is rectified.

H

The main transistor was defective during driving: The program compares the pulse pattern on the transistor base with the pulse pattern on the failsafe circuit. If the pattern does not correspond, the failsafe transistor switches off and the direction contactor drops out. The system locks in passive state.

P

Safety switch to avoid crushing injuries active: This function forces in the forward direction with a modulation of 70 % for approx. 3 seconds. After the function is completed the direction selector and the safety switch must return to neutral position before driving can continue. (Not used by Atlet AB.)

Important!

If there are undefined characters on the display then the logic card is defective and must be replaced.

10.6.6

Failsafe function

The microprocessor on the control card continuously monitors the main transistors.

Sigma Transistor - System TR 250 CS

ATLET SERVICE MANUAL

10.14

Electrical system

The Collector-Emitter voltage is compared with the signal on the base. If they do not correspond the microprocessor reacts within the space of milliseconds, and switches off the directional contactors by means of the failsafe transistor If the contactor does not drop for some reason, the inner emitter conductor to the shortcircuited power transistor will burn off and cause a break. This results in overloading of the other power transistors, so that they also burn off, causing a dead regulator with a burned resistance.

10.6.7

Other safety functions

1

Static return to neutral of the direction. When the key switch closes, the microprocesser checks if a direction is set. In which case a 2 is shown on the display and the system does not pulse before the directional selector has been reset to neutral position and been actuated again.

2.

Contactor test: When both directional contactors are pulled simultaneously the display shows A, and the system does not pulse.

3.

Undervoltage protection: Uncontrollable situations can occur if the battery voltage falls below 10.5 volts. A safety circuit therefore prevents the program from starting, and resets the system until the battery voltage reaches a reasonable level again. In most cases the display shows a 2 and must be reset by moving the speed controller to neutral.

4.

Temperature monitoring: The power unit is protected from high temperatures by a thermistor. If it rises over +85 C the thermistor limits the throttle signal and therefore the maximum current. If the temperature drops it is once again possible to give the motor full power.

5.

Overcurrent protection: If a transistor is exposed to higher current than it can withstand, it will be destroyed. There is therefore a safety circuit in the system that monitors excessively high current. The monitoring switches off just as the current reaches the lower level of the set current limit.

6.

Overload protection: The microprocessor monitors the voltage drop over the collector-emitter on the main transistors. If the voltage drop is too high this will lead to high power losses and excessive development of heat in the transistor, which can destroy the component. This saturation voltage is therefore continuously monitored, and if it rises over a certain level the system is switched off. (Approx. 2.5 Volt) This is experienced as if the top speed is somewhat lower than normal.

10.6.8

Test of safety functions

Important!

To conduct the tests the truck must be lifted up so that the drive wheel turn freely.

All tests are conducted with the voltage on. If the tests do not show the required results, the unit will not be approved.

ATLET SERVICE MANUAL

Sigma Transistor - System TR 250 CS

Electrical system

10.15

TEST 1 1

Disconnect the battery plug, and short-circuit between collector and emitter.

(C and E)

2.

Connect the voltage again. The display should now show a flashing F, and it will not be possible to close the contactors.

TEST 2 1

System in neutral (the display shows 3).

2.

Short-circuit between C and E. The display should now show a flashing F, and it will not be possible to get the contactors in.

TEST 3 1

While driving. Give full throttle so that the display shows a minus character, which implies that the main transistors are fully open. (Speed 100%).

2.

Short-circuit between C and E.

3.

Release the speed controller down to approx. 75%.

4.

The display should now show a flashing H, and the directional contactor should now switch off.

10.6.9

Connections and voltage values

Starting point: Plug in, key on, and foot pedal pressed.

Table 10.3 Switch T Drive regulator

Pin

Function

Cable colour

Inactive

Active

1

detecting contactor forward

yellow

B+

approx. 0 V Same as switch T 12

2

detecting contactor backward

violet

B+

approx. 0 V Same as switch T 12

3

speed limiting (not used)

4

safety switch function (not used)

black

+5 V

+5 V

5 6 7

Plus supply to potentiometer

Sigma Transistor - System TR 250 CS

ATLET SERVICE MANUAL

10.16

Electrical system

Table 10.3 Switch T Drive regulator

Pin

Function

Cable colour

Inactive

Active

8

B- supply to the transistor system

blue

B-

B-

9

voltage from potentiometer

white

approx.

0.4 V

approx. 5.0 V

Minus outlet to contactors

blue

0 Volt

approx. 1.5 Volt lower than B-

15

B- supply to the potentiometer

green

16

B+ supply to the transistor system’s circuit board

grey

B+

B+

10 11 12

13 14

Warning!

Make sure that pin 3 is not connected when replacing the control card.

ATLET SERVICE MANUAL

Sigma Transistor - System TR 250 CS

Electrical system

10.17

10.6.10 Trouble shooting SIGMA 250 TR Directional contactor does not function

Is battery voltage found across the contactor coil?

Yes

Change contactor!

No Is the control fuse intact?

No

Change fuse!

Yes Is the circuit on the contactor plus side OK?

No Repair circuit!

Yes Is the cable on pin T16 OK?

No

Repair cables or change key switch!

Yes Is the circuit on the coil negative side OK?

No

Repair circuit!

Yes Change control board!

SM078-1E

Figure 10.4 Trouble shooting chart

Sigma Transistor - System TR 250 CS

ATLET SERVICE MANUAL

10.18

Electrical system

The contactors function, but not the speed controller

No Flashing point on display?

No Is there battery voltage between T16 and T8?

Check cable harness to contact T !

Yes

Yes

Yes Is the voltage 10.5 V or higher between T16 and T8?

Change PCB !

No Check the battery voltage!

Charge the battery !

Check for voltage drop between battery and contact T! Yes

Check that the directional switch is in neutral when starting the truck.

Check direction switch input T1 &T2

Yes

Check that there are no short circuit in circuit over master transformer or interruption in the power unit !

Change power module

Display shows "2"

No

Display shows "F" or "H"

No Yes Display shows "A"

Check the speed controler!

Check direction switch input T1 & T2 !

sm090-2E

No

Figure 10.5 Trouble shooting chart

ATLET SERVICE MANUAL

Sigma Transistor - System TR 250 CS

Electrical system

No Controller pulsate?

10.19

No

Check that the accelerator signal is OK?

Repair or change accelerator !

Yes

Yes

No Check that connection 7B - Base T7 is OK?

Repair connection or change power module!

Yes

Change PCB !

Display shows "4", "5", "6", "7", "-" when increasing accelerator signal?

Yes

No Is the motor running?

Check motor and connections?

No No Display shows "8"

If the display show undefined characters then change PCB !

Yes Is the motor to be braked electrically?

No Is 4B and 5B connected to top of each field?

No

Repair connections or change power module!

Yes Change PCB ! sm091-2E

Figure 10.6 Trouble shooting chart

Note!

B is the second small connector on the logic card, the cables of which go the drive regulator.

Sigma Transistor - System TR 250 CS

ATLET SERVICE MANUAL

10.20

Electrical system

The front connector is also actuated if the directional selector is in reverse or neutral.

Display shows "P" ?

No

Change contactor RK!

No

Yes

Check if there is connection to T4.

Yes Contactor welded?

No

Change PCB !

Yes

Remove the connection!

sm092-2E

Figure 10.7 Trouble shooting chart

Note!

If the display shows undefined characters, the control card should be replaced!

ATLET SERVICE MANUAL

Sigma Transistor - System TR 250 CS

Electrical system

10.7

10.21

Curtis 1207 0

Curtis 1207 is a system to regulate the speed on series-wound DC motors.

The power unit is based on MOSFET technology.

The system pulses at a frequency of 15 kHz at a low intensity, so it is in practice noiseless.

There are two exceptions from the high pulse frequency.

1

During reverse braking the system pulses at a lower frequency: 1.5 kHz. The reason for this is that a more precise control is required of the relatively low current pulsed to the motor on this occasion. The main part of the motor current goes in the motor and free-wheel diodes.

2.

When the system temperature is less than minus 25 degrees. The system withstands temperatures down to minus 40 degrees, but to reduce the strain on the capacitors the current capacity is reduced. To indicate this the system pulses with an audible frequency. Even if the truck has stood in the cold store during the night, the temperature inside the system will quickly rise to a value over minus 25 degrees and then provide full current again.

There is a Hand terminal for the system, which can be used during adjusting work and trouble shooting. This is described in section 10.7.1. Even without the Hand terminal it is possible to adjust the settings, but in this case the potentiometers under the cover on top of the system are used. On certain systems the potentiometers are intentionally disconnected through programming, e.g. for systems that are out for test purposes.

The system is protected from overvoltage and undervoltage, including excess temperatures.

Curtis 1207

ATLET SERVICE MANUAL

10.22

Electrical system

10.7.1

Hand terminal

D IA

GN

O ST

IC S

ST TE M RA OG PR GE AN E CH A L U V LL RO Y SC PL A D IS

O INF RE MO

SM O48.1

Figure 10.8 The hand terminal is used for adjustments and trouble shooting. The terminal is connected to the Curtis system via a connector under the cover on the opposite corner to the cable connections.

Important!

When the Hand terminal is connected to the system the brake switch must be switched off until the terminal shows the system’s Model number, Manufacturing date and Program version.

The Hand terminal is operated with the eight buttons on the front. The top three buttons select the type of work to be done: “PROGRAM” Used to set system parameters.

“DIAGNOSTICS" Used to read the faults registered by the system.

“TEST” Used to test input signals, output signals and temperature inside the system.

The following buttons are used to browse through the menus and to change settings: “SCROLL DISPLAY” Browse in the menu. The current line is the top one in the display with the flashing arrow.

“CHANGE VALUE” Changes the value or function of the set parameter.

“MORE INFO” Here you can obtain more detailed information on the set function.

ATLET SERVICE MANUAL

Curtis 1207

Electrical system

10.7.2

10.23

Special Program

By first pressing “More info” and holding this pressed when pressing “Program”, you can access special programs with functions as shown in the table 10.4: Table 10.4 Display - text

Explanation

RESET ALL SETTINGS

Return to previous settings. Can only be done if the system has not been dead, or the Hand terminal has not been disconnected after adjustments have been changed.

CONT SETTINGS -> PROG

Transfers system settings to the Hand terminal.

PROG SETTINGS -> CONT

Transfers the Hand terminal’s settings to the system.

CLEAR DIAG HISTORY

Clears the system’s diagnostic history.

CONTRAST ADJUSTMENT

Adjusts the display’s contrast.

LANGUAGE SELECTION

Selects language in the Hand terminal. (Swedish unfortunately not available today).

PROGRAMMER INFO

Shows Hand terminal information.

CONTROLLER INFO

Shows system information.

10.7.3

Special Diagnostic

By pressing “More info” and holding it pressed while pressing “Diagnostics” you can access a function which enables you to read the system’s diagnostic history stored since it was last cleared. To access the register with diagnostic history the brake switch in the truck must be open, i.e. the brake applied. The Min and Max temperatures are in the system’s “Test” menu. Each fault is only registered once, regardless of how many times it has occurred. To clear diagnostic history set the Hand terminal in “Special Program” mode, select “Clear Diagnostic History” and press the button “More Information” for more information. The Min and Max temperatures in the “Test” menu are also cleared when clearing diagnostic history.

10.7.4

Programming

Each time a Hand terminal is connected to a system the system’s set values are saved in a temporary memory in the Hand terminal. If you change these settings you can recall the original settings in “Special Program Menu”. Select “Revert to Previous Settings”, press the “Menu” button and follow the instructions. This only functions while the Hand terminal is connected to the system and the system has not been disconnected during this period.

10.7.5

Adjustment instructions

Curtis 1207 can be adjusted in three ways.

Curtis 1207

ATLET SERVICE MANUAL

10.24

Electrical system

Important!

After adjusting, the adjusting cover must be closed for the system to withstand humid environments.

With Hand terminal.

This method is to be preferred instead of potentiometers. For operation, see section 10.7.2.

With built-in potentiometers.

This method is more time consuming since it must be carried out together with measurements of currents, speeds and other performance data. For current limit setting the current is measured in one of the motor cables, with the rotation of the motor mechanically locked and full throttle on the speed controller. The speed setting is made by adjusting and verifying the setting, and measuring the speed. Not all the parameters in the Hand terminal are accessible with potentiometers. To return to adjusting with the Hand terminal when the potentiometers have been used they must be set to Off mode, i.e. adjusted max to the left.

The potentiometers for current limits are not functional when low speed is selected, or if “Anti-Tiedown” is active.

On certain systems the potentiometer functions are disconnected at the factory.

By copying between two systems (“Cloning”) When a system is adjusted and it is necessary to have additional systems adjusted to the same values, this can be done by saving the current values in the Hand terminal’s memory and connecting it to the system where you want to copy the same settings.

When copying between two systems they have to be of the same type and have the same program version.

Copying from a system to the Hand terminal 1

Connect the Hand terminal to the system.

2.

Adjust in the required values to the system.

3.

Press the “More info” button, and keep it pressed.

4.

Press the “Program” button.

5.

Step down to “CONT SETTINGS -> PROG” with the “Scroll” button.

6.

To save the values from the system to the Hand terminal, press “More info”.

7.

The Hand terminal responds: ALL CONT SETTINGS SAVED IN PROGRAMMER CONFIRM VALUE UP CANCEL VALUE DOWN This means that if you want to complete the transfer, press:

ATLET SERVICE MANUAL

CHANGE VALUE

Curtis 1207

Electrical system

10.25

CHANGE VALUE

If you want to cancel, press:

The Hand terminal responds: “......WORKING” After which: ALL CONT SETTINGS SAVED FROM PROGRAMMER 8.

Return to the main menu by pressing “Program”.

Copying from the Hand terminal to another system.

1

Connect the Hand terminal to the system you want to copy the values to.

2.

Press the “More Info” button, and keep it pressed.

3.

Press the “Program” button.

4.

Step to “Prog settings -> Contr.

5.

To copy the values from the Hand terminal to the system, press “More Info”.

6.

The Hand terminal responds: ALL VALUES SAVED IN CONTR CONFIRM VALUE UP CANCEL VALUE DOWN This means that if you want to complete the copying, press:

CHANGE VALUE

CHANGE VALUE

If you want to cancel, press: 7.

The display then shows: “......WORKING” After which: ALL PROG. SETTINGS SAVED IN CONTR

8.

Copying is completed.

9.

To copy to additional systems, repeat 1-7.

10. To return to the main menu, press “PROGRAM”.

Curtis 1207

ATLET SERVICE MANUAL

10.26

Electrical system

10.7.6

Available adjustment parameters

Table 10.5 The display shows:

Function

EMR REV C/L

Current limit during emergency reversing

RAMP C/L

Current limit during ramp start.

THROTTLE TYPE

Selection of throttle type.

Type 1: 5K-0 Potentiometer Type 2: 0-5 V Pot. or Electronic sensor Type 3: 0-5K

Potentiometer

RAMP SHAPE

Speed in % of top speed, at 50 % throttle on the speed controller.

CREEP SPEED

Pulsing when the directional contactor closes without additional throttle.

EMR REV SPEED

Low speed in % of top speed during emergency reversing.

SEQUENCING DLY

Delay of HPD during short interruptions in the key switch.

Setting in seconds.

VARIABLE PLUG

Selection of adjustable reversing brake with the speed controller.

On or Off.

HIGH PEDAL DIS *1

Type 0 = No HPD. Type 1 = HPD on brake switch Type 2 = HPD on key switch

SRO *2

Type 0 = No SRO Type 1 = SRO on brake switch Type 2 = SRO on both key switch and brake switch

ANTI-TIEDOWN

Requirement that the switch is in neutral during start up.

Selection of function. On / Off

QUICK START

Quick start of throttle factor.

MAIN C/L

Current limit

PLUG C/L

Current limit during reverse braking

ACCEL RATE

Acceleration delay

M1 MAX SPEED

Max speed in top speed position

M2 MAX SPEED

Max speed in reduced speed position

NEUT BRAKE C/L

Current limit during Autoreversing (Braking force)

NEUT BRAKE ON/OFF

Autoreversing On / Off

*1 = HPD (High Pedal Disable) type 1 and 2 monitor that the voltage from the speed throttle (pot.) lies below 25 % of full response when the brake switch or key switch are switched on.

ATLET SERVICE MANUAL

Curtis 1207

Electrical system

10.27

*2 = SRO monitors that the brake switch or key switch are not switched on during direction selection.

10.7.7

Adjusting values

Table 10.6 The display shows:

A

EMR REV C/L

25 Not used

RAMP C/L

250

THROTTLE TYPE

2

RAMP SHAPE

30

CREEP SPEED

“Pull position”

EMR REV SPEED

50 (Not used)

SEQUENCING DLY

2.0

VARIABLE PLUG

On

HIGH PEDAL DIS

Type 2

SRO

Type 0

ANTI-TIEDOWN

Off

QUICK START

0

MAIN C/L

250

PLUG C/L

70

ACCEL RATE

0,7

M1 MAX SPEED

100

Speed during top speed position

M2 MAX SPEED

*1

Speed in reduced position

NEUTR BRAKE C/L

50

NEUTR BRAKE

Off

*1 = Set to reduced speed of 2.5 km/h

Note!

Not all the above parameters are accessible with all Hand terminals.

Curtis 1207

ATLET SERVICE MANUAL

10.28

Electrical system

10.7.8

Function and installation check Curtis

Before the truck is used after assembling or major work on the electrical system, the following must be checked. The checks can be made with or without the Hand terminal. The LED for status and fault indicating are used if the Hand terminal is not available.

Warning!

During function checks the truck must for safety reasons be jacked-up, with the drive wheel over the floor.

Before the battery plug is connected, make sure that: • The key switch is disconnected.

• The brake switch is inactivated.

• The speed controller is in neutral.

Warning!

Do not stand, or allow anyone else to stand, in front of or behind the truck.

1

Push up the cover on the top of the regulator. The cover is not removable. If a Hand terminal is available, connect it.

2.

Switch on the key switch. The Hand terminal’s display should now light up.

The LED should start flashing steadily with single flashes. If not, check that there is voltage between pin 16 on the control connector and B-.

If the battery is on but the LED still does not light up, replace the system.

3.

If the Hand terminal is used, connect the Diagnostics function by pressing the button marked “Diagnostics”.

The display should now show “No fault”.

Release the brake (close the brake switch); the LED should still flash with one flash in fast frequency. The Hand terminal’s display should still show “No Fault”.

If something is defective the LED will show a code by flashing a sequence of flashes in two groups, with an interval between. This is repeated until the fault is rectified. The Hand terminal will show a fault message.

If you are doing the check without the Hand terminal, check Diagnostics and Trouble Shooting to translate the flashes to a text fault message. There are also translations of the Hand terminal’s English texts.

When the fault is rectified it may be necessary to switch the brake switch off and on to clear the fault message.

4.

The speed controller is actuated with the brake released, and the motor should then rotate in the selected direction. If this does not happen, check the directional switches, directional contactors, the motor, and the cabling. The motor should rotate proportionally to the throttle. If not, read the trouble shooting instructions.

ATLET SERVICE MANUAL

Curtis 1207

Electrical system

10.29

5.

If you are using the Hand terminal, connect the test function by pressing the button marked “Test”. Browse down by pressing the button “Scroll” and check that the position of the different switches correspond between the Hand terminal and the actual position. Check also that the speed controller varies from 0-100%.

6.

Set down the truck on the floor, and drive in a free area. It should have smooth acceleration, good top speed, and good response.

7.

Test the reversing brake by changing direction while driving. The truck should then brake to a stop and directly afterwards start in the opposite direction. The braking force should be adjustable with the speed controller. If it is not, check that the setting of “Plug brake” in “Program” mode is set to “Variable”.

8.

When the checks are complete, make sure that the cover over the connector for the Hand terminal is closed.

2 3 1 4 0 2 3 F LOW 1 F 4O IT 0 2 IM P E 3 L F 1 F CRE EED 4 O. SP 0 2 L E 3 1 FF ACC 4O 0 2 G 3 1 FF P LU T I 4O M 0 I IN TL F OF MA RREN CU

US AT ST

SM O47.1

Figure 10.9 Curtis 1207 steering unit

Curtis 1207

ATLET SERVICE MANUAL

10.30

Electrical system

10.7.9

Trouble shooting by means of LED

During normal operation the LED should flash with a steady frequency of approx.

1 flash per second.

If the system detects a fault the LED starts to flash a two-digit code until the fault is rectified.

Example

¤¤ ¤¤¤

¤¤ ¤¤¤

¤¤ ¤¤¤

(2

(2

(2

3)

3)

3)

Check the code 2,3 in table 10.7.

Table 10.7 Codes

Explanation

Off

System without voltage or defective

Steady

System defective

Single flash

¤

System in operation and should function as normal

1,2

¤ ¤¤

Circuit fault in the safety system. System defective

1,3

¤ ¤¤¤

1. M- terminal short-circuited to B2. Directional contactor does not close.

3. Directional contactor does not close quickly enough.

4. Internal fault in the system.

1,4

¤ ¤¤¤¤

1. Directional switch closed when the key switch or brake switch is closed.

2. Incorrect type of SRO selected. See Installation instructions, check selected SRO.

2,1

¤¤ ¤

Fault in input from 5K - 0 potentiometer. Not used by Atlet.

Reselect in Program mode. See Installation instructions.

2,2

¤¤ ¤¤

Fault in the emergency switch circuit for reverse turning.

1. Break in cable to Emergency switch.

2,3

¤¤ ¤¤¤

HPD fault. Incorrect start up. Start again with all switches in neutral.

2,4

¤¤ ¤¤¤¤

1. Low Input from potentiometer not connected or shortcircuited to B+ or B2. Incorrectly adjusted speed potentiometer.

3. Incorrect potentiometer type selected in the settings program. See Installation instructions.

3,1

¤¤¤ ¤

Short-circuit in the directional contactor’s coil or circuits around this.

3,2

¤¤¤ ¤¤

Directional contactor has stuck in closed position or external short-circuit.

3,3

¤¤¤ ¤¤¤

(Reserved for future use)

ATLET SERVICE MANUAL

Curtis 1207

Electrical system

10.31

Table 10.7 Codes

Explanation

3,4

¤¤¤ ¤¤¤¤

1. Directional contactor does not close or 2. Open motor circuit.

4,1

¤¤¤¤ ¤

Low battery voltage. Lower than 16 Volt

4,2

¤¤¤¤

Overvoltage. Over 45 Volt on 24 volt system.

4,3

¤¤¤¤ ¤¤¤

The system’s temperature monitoring has been activated. ( < 25 degrees or > +85 degrees.)

4,4

¤¤¤¤ ¤¤¤¤

(Reserved for future use)

¤¤

10.7.10 Trouble shooting by means of Hand terminal Switch off the key switch and brake switch before connecting the Hand terminal.

The Hand terminal is connected to the outlet under the service cover on the transistor system. Start up the system and try to drive. Read off the display text, and compare with table 10.8 below.

Table 10.8 Display - text

Explanation

DISPLAY OFF

System without voltage or defective

HW FAILSAFE

Circuit fault in the safety system. System defective

M- FAULT

1. M- terminal short-circuited to B2. Directional contactor does not close.

3. Directional contactor does not close quickly enough.

4. Internal fault in the system.

SRO

1. Directional switch closed when the key switch or brake switch is closed.

2. Incorrect type of SRO selected. See Installation instructions, check selected SRO.

THROTTLE FAULT 1

Fault in input from 5K - 0 potentiometer. Not used by Atlet.

Reselect in Program mode. See Installation instructions.

BB WIRING CHECK

Fault in the circuit for reverse turning in emergency situation. Break in cable to the above circuit. Only used on TL models.

HPD

HPD fault. Incorrect start up. Start again with all switches in neutral.

Incorrect HPD type may be selected in “Program” mode.

Incorrectly adjusted speed throttle, too high voltage to the system in neutral.

Curtis 1207

ATLET SERVICE MANUAL

10.32

Electrical system

Table 10.8 Display - text

Explanation

THROTTLE FAULT 2

1. Minus connection in the speed throttle not connected or short-circuited to B+ or B2. Incorrectly adjusted speed potentiometer 3. Incorrect potentiometer type selected in the settings program. See section 10.7.5

CONT DRVR OC

Short-circuit in the directional contactor’s coil or circuits around this.

DIR CONT WELDED

Directional contactor has stuck in closed position or external short-circuit.

MISSING CONTACTOR

1. Directional contactor does not close or 2. Open motor circuit.

LOW BATTERY VOLTAGE

Low battery voltage. Lower than 16 Volt.

OVERVOLTAGE

Overvoltage. Over 45 Volt on 24 volt system.

THERMAL CUTBACK

The system’s temperature monitoring has been activated. < 25 degrees or > 85 degrees.

10.7.11 Trouble shooting by means of Test menu With the help of the Hand terminal you can read off the status on inputs and outputs in the system’s control connector.

The display shows what the system interprets of the input status. If measurements directly on the control switch produce another result, this may be because of poor contact in the plug or that the system is defective.

The display shows respective input status in the form of “On” if the input has voltage and “Off” is there is no voltage. Where a value can be expected, it is shown.

1

Press the “Test” button.

2.

The display now shows the upper inputs.

3.

Test them by actuating the respective input and checking if the display shows the expected value. If not, investigate the reason.

Test menu Table 10.9 The display shows

Function

FORWARD SWITCH

Directional switch for Forward

On / Off

REVERSE SWITCH

Directional switch for Reverse

On / Off

BRAKE SWITCH

Brake switch actuated

On / Off

ATLET SERVICE MANUAL

Curtis 1207

Electrical system

10.33

Table 10.9 The display shows

Function

THROTTLE %

Voltage from speed controller

% of full throttle

SPEED SWITCH

Speed switch

On / Off

EMP REV SWITCH

Emergency reversing switch

On / Off

MAIN CONTACTOR

Main contactor (not applicable on Atlet trucks)

FWD CONTACTOR

Forward contactor (Output)

On / Off

REV CONTACTOR

Reverse contactor (Output)

On / Off

BATT VOLTAGE

Battery voltage (measurement value)

HEAT SINK C

Temperature of the system’s surface chill

MAX TEMP C

Maximum temp. since the fault log was cleared

MIN TEMP C

Minimum temp. since the fault log was cleared

10.7.12 Specifications System specifications for Curtis 1207 Table 10.10 Curtis 1207

Battery voltages:

Curtis 1207

Nominal

24V-36V

Max operating voltage

45V (Overvoltage point)

Min operating voltage

16V (Undervoltage point)

Insulation voltage to cooling flange

500 V AC minimum

Pulse frequency

15 kHz (1.5 kHz during reversing and less than 25 degrees on the cooling flange.)

Max contactor current

1A

Current consumption control current

80 mA ( 130 mA with connected Hand terminal)

Logical threshold for inputs

8V

Ambient temperature

-40 - + 50 degrees Celsius.

Temperature monitoring (internal)

+85 degrees - + 95 degrees 100%-0% current limit

Lower temperature limit (internally in the system)

-25 degrees (50% of current limit)

ATLET SERVICE MANUAL

10.34

10.8

Electrical system

Side stabilisers 0

A – trucks can be fitted with extendable side stabilisers to guarantee lateral stability and to eliminate the risk of tipping during high lifts. The system consists of extendable support arms, which are extended by means of the standard hydraulic unit. On the instrument panel there are two control lamps, which indicate if the support arms are extended (red lamp, forks can be lifted to maximum position) or withdrawn (green lamp, forks can only be lifted to their lifting height limit position).

A microswitch on the mast limits the lifting height when the support arms are withdrawn. When the support arms are extended the microswitch gives a signal that the forks can be lifted to their maximum position.

Important!

If the truck is equipped with side stabilisers, this is a safety function that must be in operation and function correctly.

SM 074.1

Figure 10.10 Truck with side stabilisers

ATLET SERVICE MANUAL

Side stabilisers

Electrical system

10.8.1

10.35

Adjusting

The microswitch that limits the lifting height when the support arms are in withdrawn position should switch as shown in table 10.11: Table 10.11 Weight

Lifting height*

1250 kg

3000 ± 25 mm

1600 kg

2500 ± 25 mm

2000 kg

2000 ± 25 mm

*) The height the forks should be able to be lifted before the microswitch breaks.

When the support arms are extended and reach their fully extended position the pump motor and support arms should stop. The distance between the floor and stabiliser wheel when the motor has stopped should be 0 mm, see figure 10.11. The floor should be level when checking! Because of the motor’s inertia the microswitch should break before the wheel reaches the floor, at 10-20 mm above the floor.

0 mm

Figure 10.11 Stabiliser wheel The residual suspension with fully extended support arms should be 10-12 mm.

The point in time when the pump motor stops is determined by the microswitches (four) located at the support arm attachments. Check the distance between arm and switch when the microswitch is actuated (pressed in); it should be 1.2 mm, see figure 10.12.

1

1,2 mm E

4 2

Figure 10.12 Microswitch

Side stabilisers

ATLET SERVICE MANUAL

10.36

10.9

Electrical system

Wiring diagram 0

Table 10.12 Description

Machine type

Reference

Document code

Wiring diagram, thyristors

A / ATF

old

058600

Wiring diagram, thyristors

A / ATF

old

058600

Wiring diagram, transistors

A / ATF

old

059100

Wiring diagram

A / ATF

060300

Wiring diagram

A / ATF

060301

Wiring diagram extra accessories

A / ATF

060290

Wiring diagram extra accessories

A / ATF

060312

ATLET SERVICE MANUAL

Wiring diagram

SERVICE MANUAL Machine: A-86 Manual No: 005940

Edition 2001A

Brake system 11.1 Hydraulic brake......................................................................................................... 11.1 11.1.1 Brake unit ..................................................................................................................11.3 11.1.2 Brake drum ...............................................................................................................11.4 11.1.3 Brake shoes, replacing ..............................................................................................11.4 11.1.4 Main cylinder ............................................................................................................11.5 11.1.5 Replacing the brake cylinder ....................................................................................11.5 11.1.6 Brake fluid and bleeding ...........................................................................................11.5 11.1.7 Brake adjusting .........................................................................................................11.6 11.2 Electric brake ............................................................................................................ 11.8 11.2.1 Electric brake 1 stage, 1 disc ....................................................................................11.8 11.2.2 Adjusting the electric brake ......................................................................................11.9

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Brake system

11.1

Edition 2001A

11 Brake system 11.1

Hydraulic brake 0

The mechanical brake system consists of a main brake and on some machines a parking brake, which has the same brake shoes.

On the motor shaft there is a brake drum, to which two brake shoes are pressed by spring tension. When the driver pushes on the foot pedal this actuates the brake system’s main cylinder, which presses brake fluid to a slave cylinder. The slave cylinder counteracts the spring pressing the brake shoes against the brake drum, whereby the motor shaft can turn freely.

Some trucks have a pedal with a locking device, which is to reinforce the parking brake when parking.

On the main cylinder there is a pressure switch, which supplies control current to the transistor system when the driver puts his foot on the foot pedal. When the driver releases the foot pedal while driving, the control current is disconnected and the brake is applied.

Warning!

It is extremely important that the brake is correctly adjusted, otherwise there is a risk that the truck will tip backwards when braking while reversing.

SM_A_11_e_2001a.fm

Hydraulic brake

ATLET SERVICE MANUAL

11.2

Brake system

38

1

19

16 13

3

23 26

50

29

8

51 34 5 34

52

8

39 49 11

31 18

35

40

2 34 4

41 30 8

29 6

9

28

48 12

25

33 42

32 24 7

43

44

21 45

37 22

10 27

32 28

17 8

46

27 20

H 46.1

47

36

Figure 11.1 Hydraulic brake

ATLET SERVICE MANUAL

Hydraulic brake

Brake system

11.3

3

1

2 4

14

15 16

17 17 5

18

19

6 23 21

8

22

7

26 24

9 13

25

20

11

10

12

H 45.1

Figure 11.2 Brake assembly

11.1.1

Brake unit

1

Dismantle the lower machine housing cover.

2.

Swing forward the brake device by turning the wheel.

3.

Remove the retaining bolts, pos. 16 figure 11.2.

4.

Press down the foot pedal by hand and lift out the brake assembly.

Hydraulic brake

ATLET SERVICE MANUAL

11.4

Brake system

5.

Place a pair of hose clamp pliers on the brake hose and release it from the slave cylinder, and then lift out the complete brake device.

6.

Assemble in the reverse order. Use new sealing washers, bleed and then adjust.

11.1.2

Brake drum

Dismantling 1

Dismantle the lower machine housing cover.

2.

Swing forward the brake device by turning the wheel.

3.

Remove the complete brake device.

4.

Unscrew the nut that locks the brake drum on the drive motor shaft.

5.

Remove the brake drum with a suitable withdrawing tool.

Assembly 1

Fit the brake drum by guiding the key into the V-groove in the drum, and press the drum on the drive motor shaft. Tap carefully with a hammer if necessary.

2.

Fit the nut with a tightening torque of 30 Nm.

3.

Fit the brake device and check the clearance between the brake shoes. Adjust if necessary.

11.1.3

Brake shoes, replacing

The brake shoes must be replaced when the thickness of the lining is less than 2 mm.

The wear on the brake drum must also be checked when replacing the brake shoes.

The external diameter of the brake drum must not be less than 118 mm in diameter.

Dismantling the brake shoes 1

Release the adjusting screw, pos. 23 figure 11.2, and unhook the spring, pos. 20.

2.

Remove the circlips, pos. 19, and the washers, pos. 17, and then pull loose the shoes.

Assembling the brake shoes 1

Check the bushings in the shoes, and replace if they are worn.

2.

If new brake shoes are fitted and they have no bushings, it is possible to transfer the bushings from the old brake shoes if they are not worn.

3.

Work the brake shoes on the pins they sit on, and fit the washers and lock rings, pos. 17 + 19.

4.

Fit the spring and draw bolts with the lock nuts, pos. 20 + 24 + 25.

5.

Adjust, see section Adjusting the brake 11.1.7.

ATLET SERVICE MANUAL

Hydraulic brake

Brake system

11.1.4

11.5

Main cylinder

1

Lift up the truck in the rear end and secure with blocks.

2.

Place a container under the truck and remove the banjo screw, pos. 42 figure 11.1.

3.

Release the oil pipe, pos. 41.

4.

Remove the bolts, pos. 24, and lift out the main cylinder.

Assemble in the reverse order; use new copper washers, pos. 43 + 45.

Bleed after assembling, see section Bleeding 11.1.6.

11.1.5

Replacing the brake cylinder

1

Place a pair of hose retaining pliers on the brake hose to the brake cylinder.

2.

Release the pipe bend screwed in the brake cylinder.

3.

Loosen the retaining screw, pos. 5 figure 11.2, and lift out the cylinder.

4.

Assemble in the reverse order.

Bleed the system after assembling, see section 11.1.6.

When the system has been bled, adjust; see section 11.1.7.

11.1.6

Brake fluid and bleeding

The safest way of bleeding the system is to lock the brake cylinder first so that it cannot move.

1

Screw in the adjuster for the brake shoes so that it presses against the brake drum, or place a suitable object between the brake shoes and the brake drum.

2.

Check the brake fluid level.

3.

Place a box spanner on the air screw located on the back of the brake cylinder. Place a transparent hose outside the box spanner and place the other end in a bottle to collect the spillage.

4.

Press the brake pedal fully down, and keep it pressed. Open the air screw and allow any air to flow out.

5.

When the pedal has reached its lowest position, close the air screw and release the pedal up.

Important!

Check that there is still fluid in the reservoir.

6.

Repeat point 4 until no air comes with the brake fluid: check by looking at the hose.

7.

Adjust the brake shoes, or remove the object locking the shoes, see section 11.1.7.

Hydraulic brake

ATLET SERVICE MANUAL

11.6

Brake system

8.

Fit the covers and panels.

9.

Test drive and check the function.

11.1.7

Brake adjusting

1

Adjust dimension A in figure 11.3 to 2 mm on each side.

2.

Adjust dimension B to 1 mm on each side.

3.

Adjust dimension C to 45 mm.

4.

Adjust the distance between the top edge of the brake pedal and the floor to 40-45 mm.

5.

Adjust the distance between the push rod and the piston in the main cylinder to 1 mm, dimension D in figure 11.4.

6.

Check the braking distance by driving unloaded at top speed and braking.

Table 11.1 Type

Max Braking distance without load

A100

1.7 m

A 125

1.6 m

A 160/200

1.4 m

ATF

1.5 m

ATLET SERVICE MANUAL

Hydraulic brake

Brake system

11.7

A

A

B

B

SM 081.1

C Figure 11.3 Dimensions when adjusting the brake

D p 85166.2

Figure 11.4 Dimensions when adjusting the brake

Important!

The drive wheel must not lock when testing the brake.

Important!

The load wheel must not leave the ground when testing the brake.

Important!

Observe care so that the truck does not tip backwards when testing the braking distance. Always test in the direction of the forks first.

Hydraulic brake

ATLET SERVICE MANUAL

11.8

11.2

Brake system

Electric brake 0

The truck is braked with an electric brake if it has servo steering. The electric brake is a safety brake with two friction surfaces. The braking torque, which can be adjusted with one adjusting screw, is created by spring pressure. The brake releases electromagnetically when actuated by a switch placed in the brake pedal. The brake releases in one stage.

11.2.1

Electric brake 1 stage, 1 disc

When the brake is activated the springs, pos. 6. figure 11.5, press on the plate, pos.

7, which is pressed axially to the rotor, pos. 9. When the brake is to be released the coil, pos. 5, is supplied with battery voltage. The magnetic field created between the plate, pos. 7, and the magnetic part, pos. 5, allows the rotor to rotate freely.

ATLET SERVICE MANUAL

Electric brake

Brake system

11.9

4 1

2

5

6

6

7

8 3

9

10

12

11

H 34.4

Figure 11.5 Electric brake

11.2.2

Adjusting the electric brake

Adjusting is carried out in the following order.

Electric brake

ATLET SERVICE MANUAL

11.10

Brake system

1

Adjusting of A dimension: Fit the electric brake and tighten the bolts. Check the distance (A), see figure 11.6, between the magnetic part and the plate. If the distance needs adjusting, release the bolts holding the brake and turn the adjusting sleeves. Tighten the brake and check that the distance is the same all round.

A dimension = 0.2 mm

2.

Adjusting the T dimension: Turn the adjuster with a hook spanner to the correct distance.

T dimension = 2.5 mm

3.

Test the brakes by driving and test braking. Braking distances are measured at max speed. Loaded means with the rated weight and a truck equipped as standard.

Braking distance without load: See section 11.1.7, “Brake adjusting,” on page 6.

T

A SM104.1

Figure 11.6 Electric brake

Warning!

Remember to lock any adjustments!

Warning!

Check that you have a safe braking capacity.

Warning!

The friction lining must be at least 1 mm, otherwise it must be replaced.

Note!

When you install a new brake, remember to remove the transport lock.

ATLET SERVICE MANUAL

Electric brake