Atlet OP Series OPM OPH OPC & OPS Service Manual - PDF DOWNLOAD

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2008B

General information and technical data

1.1 Introduction ...................................................................................................................1.1 1.2 General information, OP series ...................................................................................1.2 1.3 How to use the manual .................................................................................................1.3 1.3.1 History .............................................................................................................1.3 1.3.2 Symbol key ......................................................................................................1.4 1.4 Tips before next step ....................................................................................................1.5 1.4.1 Lifting points ....................................................................................................1.5 1.4.2 Safety instructions ...........................................................................................1.6 1.4.3 General safety risks when working on fork trucks ...........................................1.6 1.4.4 Environmentally hazardous waste – environment ...........................................1.7 1.4.5 Handling ..........................................................................................................1.7 1.4.6 Trouble shooting ..............................................................................................1.8 1.5 Data OP ..........................................................................................................................1.9 1.6 Dimensions and weights ............................................................................................1.13 1.6.1 Dimensions OP .............................................................................................1.13 1.7 Overview of motor compartment ...............................................................................1.14 1.8 Component specification ...........................................................................................1.15 1.9 Tightening torque .......................................................................................................1.17 1.9.1 Conversion table ...........................................................................................1.18 1.9.2 Bolt types and tensile grades ........................................................................1.18

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

1.10 Lubrication chart ...................................................................................................... 1.20 1.10.1 Lubrication chart OP ................................................................................... 1.20 1.10.2 Symbol explanations, lubrication chart ....................................................... 1.21 1.11 Recommended oil and grease types ...................................................................... 1.22 1.12 Colour of the truck in accordance with NCS colour codes .................................. 1.23 1.13 Colour codes for Atlet’s wiring diagrams .............................................................. 1.24 1.14 Designations for electrical components ................................................................ 1.25 1.15 Technical abbreviations ........................................................................................... 1.26 1.16 Recommended replacement ................................................................................... 1.27

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

General information and technical data

1.1

Edition 2008B

1 General information and technical data 00000000

1.1

Introduction This manual describes the service procedures for ATLET picking trucks in the OP 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 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.

Introduction

SERVICE MANUAL

1.2

1.2

General information and technical data

General information, OP series Picking trucks in the OP series include OPM, OPH, OPC and OPS.

SERVICE MANUAL

General information, OP series

General information and technical data

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, Chassis (section 4) 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

Important changes to be taken into consideration during service on the OP models.

Table 1.1 Date 2001-03-20

Chassis no.

Changed

OP1429

New connectors for steering and speed controller units.

OP1107

New type of cable in the mast.

2001-03-20

OP1429

New attachment plate for both ends of the electric cables in the mast.

2001-03-20

OP1429

New cabling in the platform.

2001-02-20

OP1429

The E4 card has been replaced with a module with fixed resistance.

New version of regulator for main hydraulic valve, with extra electronic filter for improved reliability.

2001-06-15

OP1496

The Ergomast is welded.

Fixed forks welded at the platform.

OP1377

New type of chain. 5/8 inch.

Third chain removed.

2000-10-06

Alternative safety line available as accessory.

OP1431

2001-05-14

How to use the manual

Platform lighting changed to two halogen lamps.

New decals in new position.

ATLET SERVICE MANUAL

1.4

General information and technical data

1.3.2

Symbol key

Warning!

Used with risk of personal injury.

Important!

Used with the risk of damage to the machine.

Note!

Used for general observation.

SERVICE MANUAL

How to use the manual

General information and technical data

1.4

1.5

Tips before next step 0

1.4.1

Lifting points

A

B

SM 150.1

C

Figure 1.1 Lifting points Figure above shows where the permitted lifting points are placed on the truck.

When lifting complete truck: Lift in the first instance in the upper mast strut, point A. Make sure not to damage the hydraulic pipe between the cylinders.

Lifting with jack: Lift at point C.

Tips before next step

ATLET SERVICE MANUAL

1.6

General information and technical data

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

General 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 hydraulic unit on electric Reach Trucks. The mast, reach carriage and hydraulic unit 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).

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 hydraulic unit, they must be locked by using a 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 caused by 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.

SERVICE MANUAL

Tips before next step

General information and technical data

1.7

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

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 1.7.

Tips before next step

ATLET SERVICE MANUAL

1.8

General information and technical data

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.

SERVICE MANUAL

Tips before next step

General information and technical data

1.5

1.9

Data OP 0

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 OPM, OPC, OPH, OPS SM 151.1E

Figure 1.2 Type designations (example)

Data OP

ATLET SERVICE MANUAL

1.10

General information and technical data

ATLETAB MÖLNLYCKE SWEDEN MODELL MODEL MODELL MODELE

1

SERIE NR. SERIAL NO. SERIEN NR. NOMERO DESERIE

2

TILLV. ÅR YEAR OF MANUF. BAUJAHR AN DE FABR

3 TILLÅTEN LAST ACTUAL CAP ACITY WIRKLICHE TRAGFÄHIGKEI T CAP ACITE EFFECTIVE

Q D

H

TYNGDPUNKTSAVSTÅND LOAD CENTRE DISTANCE LASTSCHWERPUNK T DISTANCE DE CENTRE

H

MM

LYFTHÖJD LIFTHEIGHT HUBHÖHE HAUTEUR DE LEVEE

D

BATTERISPÄNNING BATTERY VOLTAGE BATTERIESPANNUNG TENSION DE LA BATTERIE VIKT UTAN BATTERI WEIGHT WITHOUT BATTERY GEWICHT OHNE BATTERIE MASSE SANS BATTERIE MINSTA BATTERIVIKT MINIMUM BATTERY WEIGHT MINDESTGEWICHT DER BATTERIE MASSE MINIMAL DE LA BATTERIE MAXIMAL BATTERIVIKT MAXIMUM BATTERY WEIGHT HÖCHSTGEWICHT DER BATTERIE MASSE MAXIMAL DE LA BATTERIE

MM

Q

KG

VOLT-DC

KG

KG

KG

Figure 1.3 Machine name-plate (–2006w36) 1.

2.

3.

Type designation.

Serial number.

Year of manufacture and warranty period in months.

SERVICE MANUAL

Data OP

General information and technical data

Model Modell

1.11

1 2 3

Serial no.

Serie nr.

Year of manufacturing Tillverknings r Weight without battery Vikt utan batteri Battery weight min.

Batterivikt min.

Battery weight max.

Batterivikt max.

Battery voltage Batterisp nning Refernce number Referensnummer

ATLET AB M LNLYCKE SWEDEN

XXXXXXXX

Q

H D

H (mm)

D (mm)

Q (kg)

SMOP_010101.eps

Figure 1.4 Machine name-plate (2006w37–)

Data OP

1 2.

3.

Type designation.

Serial number.

Year of manufacture and warranty period in months.

Note!

In cases where the machine plate has been lost or become illegible, it must be renewed immediately. In order to identify the machine's serial number, there is a plate located on each main component such as drive motor, gearbox, hydraulic unit, TMC etc. For some machines there is even a plate attached inside the battery compartment, or serial number punched on the side of the mast.

ATLET SERVICE MANUAL

1.12

General information and technical data

SER XXXXXX WEEK XXXX

SER XXXXXX WEEK XXXX

Figure 1.5 Example of plate with serial number.

Serial number

SM 153.1E

Figure 1.6 Serial number

SERVICE MANUAL

Data OP

General information and technical data

1.6

1.13

Dimensions and weights 0

B3

V

930

Dimensions OP

B

1.6.1

H3

H5

785

H6

280

2000

R2

730

L1

885

H1=85

1000 25 OK 384

L2=125 H7=175

760

H4

170

795

L3=1695 L L4

Figure 1.7

Dimensions and weights

ATLET SERVICE MANUAL

1.14

1.7

General information and technical data

Overview of motor compartment 0

5

6

4

3 1

2 SMOP_010100

Figure 1.8 Overview Table 1.2 Position

Designation

Section

1

Distribution board

10

2

Drive unit

5

3

Hydraulic unit

8

4

Hydraulic tank

8

5

Hydraulic valve

8

6

Servo motor

7

SERVICE MANUAL

Overview of motor compartment

General information and technical data

1.8

1.15

Component specification 0

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

2.1 kW

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

14:1

Oil volume

1.8 litres

Table 1.5 Hydraulic system Hydraulic system Max pressure

15 MPa (= 150 kp/cm²)

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

3.25 kW

Table 1.7 Hydraulic OPC/OPS Hydraulic unit (motor and pump) (See also section 8, Hydraulic unit) Output

6.8 kW

Table 1.8 Hydraulic unit OPH Hydraulic unit (motor and pump) (See also section 8, Hydraulic unit) Output

Component specification

4.5 kW

ATLET SERVICE MANUAL

1.16

General information and technical data

Table 1.9 Control system Control system for motor Type Curtis 1243 SEPEX

Transistor

Voltage

24 V

Table 1.10 Fuses Fuses Control fuses 2 pcs.

7.5/10 A

Pump motor fuse 1 pcs.

250 A

Drive motor fuse 1 pcs.

160 A

Steering Supply

30 A

Emergency switch circuit 1 pcs.

7.5 A

SERVICE MANUAL

Component specification

General information and technical data

1.9

1.17

Tightening torque 0

Table 1.11 Tightening torque, through hole 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 torques in the table 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 above apply.

Table 1.12 Tightening torque, pipe thread 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 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

350

140

M18 x 1.5 M20 x 1.5

M27 x 1.5

G 1/2"

G 3/4"

M27 x 2 G 1"

Tightening torque

MA (Nm) with ring

ATLET SERVICE MANUAL

1.18

General information and technical data

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

Whitworth pipe thread

M33 x 2

MA (Nm) with ring

MA (Nm) with elastic

400

140

M42 x 2

G 11/4"

600

240

M48 x 2

G 11/2"

800

300

1.9.1

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

1.9.2

Bolt types and tensile grades

Table 1.14 Figure

SERVICE MANUAL

Bolt/screw 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

MVBF

Oval head countersunk screw

4,6

Tightening torque

General information and technical data

1.19

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 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 1.9 Example of marking

Tightening torque

ATLET SERVICE MANUAL

1.20

1.10

General information and technical data

Lubrication chart 0

A

F

B

G

C

H

D

I

E

J

A/B-Service Annual Service

SM 154.1E

Figure 1.10 Lubrication points

1.10.1

Lubrication chart OP

Table 1.15 Location

Explanation

Location

Explanation

A

Mast profile – roller surfaces and slide surfaces

F

Thrust rollers – all

B

Lift chains, all

G

Speed controller’s torsion springs

C

Gates

H

Hydraulic oil, filter

D

Wheel

I

Sliding bearing

E

Gear wheel steering

J

Gearbox oil

Important!

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

SERVICE MANUAL

Lubrication chart

General information and technical data

1.10.2

1.21

Symbol explanations, lubrication chart

Table 1.16 Symbol

Explanation

Symbol

Explanation

Hydraulic oil

Hydraulic oil, change

Gearbox oil

Gearbox oil, change

Grease

Chain spray

Chain spray / oil

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

Lubrication chart

ATLET SERVICE MANUAL

1.22

1.11

General information and technical data

Recommended oil and grease types 0

Table 1.17 Brand

Gearbox oil As per API grade GL-5

Hydraulic oil As per ISO VG 32, VG 15

Grease, ball bearings

Brake fluid DOT 5

Normal

Cold store

Normal (32)

Cold store (15)

BP

BP Energear Hypo 80 W/140 EP

BP Energear SHX-S 75W/140

BP Bartran HV-32

BP Bartran SHF-S

Energrease LC 2

BP Super Disc Brake Fluid

Castrol

Hypol C 80 W/90

-

Hyspin AHW 32

Hydraulic oil OM 15 Alt:Hyspin AWH 15

LMX

-

Mobil

Mobilube HD 85 W/ 90

-

DTE 13 M SHS 32

Flowrex 1

Mobilplex 48

-

Shell

Spirax HD 85 W/ 90

-

Tellus oil TX 32

Tellus oil T 15

Retinax EP 2

-

Statoil / Exxon

Gear way G5 80 W/90

-

SHS 32

J 26

Uniway Lix 625

-

Texaco

Geartex EP-C 80 W/90

-

Rando oil HDZ 32

Rando oil HDZ 15

Hytex EP2

-

Important!

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

SERVICE MANUAL

Recommended oil and grease types

General information and technical data

1.12

1.23

Colour of the truck in accordance with NCS colour codes 0

Table 1.18 Machine colour

Designation

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

1.13

General information and technical data

Colour codes for Atlet’s wiring diagrams Table 1.19 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.

SERVICE MANUAL

Colour codes for Atlet’s wiring diagrams

General information and technical data

1.14

1.25

Designations for electrical components First letter Table 1.20 Code

Designation (Eng)

A

Component or function without its own letter in list

C

Contactor

D

Diode

E

Electronic component

F

Fuse

I

Indicator

L

Light

M

Motor

P

Plug

R

Relay

S

Switch

T

Terminal

V

Valve

W

Audible warning

Second letter Table 1.21 Code

Designation (Eng)

B

Brake

C

Control system

E

Emergency function

F

Forward

H

Hour

K

Key

L

Lowering

M

Manouvre

P

Pump

R

Reverse

S

Speed

Example SL = Switch for Lowering function

Designations for electrical components

ATLET SERVICE MANUAL

1.26

1.15

General information and technical data

Technical abbreviations Table 1.22 Magnitude

Unit

Designation

Current

Ampere

A

Voltage

Volt

V

Resistance

Ohm

Ω

Output

Watt

W

Torque

Newton metre

Nm

Pressure

Pascal

Pa

Table 1.23 Prefix 1000

kilo

k

1000 000

Mega

M

SERVICE MANUAL

Technical abbreviations

General information and technical data

1.16

1.27

Recommended replacement Hydraulic hoses are perishable, and should be replaced after 5 years.

Oil should be changed after 1000 hours of operation, or once a year.

Recommended replacement

ATLET SERVICE MANUAL

1.28

SERVICE MANUAL

General information and technical data

Recommended replacement

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2007B

Special tools

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

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Special tools

2.1

Edition 2007B

2 Special tools 00000000

2.1

List of tools Table 2.1 List of tools Tools

Figure

Part number P/N

Curtis Hand terminal

2.1

006 581

Sepex cable

2.1

103 603

Check nut extractor

2.2

103 885

Crimping tool Molex, Cable connections

-

P/N 006454

Pin extractor, Cable connector

-

P/N 006456

Lifting device

2.3

P/N 118515

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

Figure 2.1 Curtis Hand terminal with connected Sepex cable

List of tools

ATLET SERVICE MANUAL

2.2

Special tools

SMOP_020100

Figure 2.2 Check nut extractor

SM_OP_02_0001A.eps

Figure 2.3 Lifting device

ATLET SERVICE MANUAL

List of tools

SERVICE MANUAL Machine: OP Manual nr: 005949

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 Drive unit .........................................................................................................3.4 3.2.4 Steering ...........................................................................................................3.5 3.2.5 Brake ...............................................................................................................3.5 3.2.6 Hydraulic system .............................................................................................3.6 3.2.7 Electrical system .............................................................................................3.7 3.3 Code explanations ........................................................................................................3.8 3.3.1 Chassis ...........................................................................................................3.8 3.3.2 Mast ................................................................................................................3.9 3.3.3 Drive unit .........................................................................................................3.9 3.3.4 Steering ...........................................................................................................3.9 3.3.5 Brake unit ......................................................................................................3.10 3.3.6 Hydraulic system ...........................................................................................3.10 3.3.7 Electrical system ........................................................................................... 3.11

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Service

3.1

Edition 2001A

3 Service 00000000

3.1

Introduction Service should be carried out regularly 4 times a year with normal truck usage, i.e.

1000 operating hours per year. The planned service (A and B service, 250 and 500 hours) 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. The service intervals must be at shorter intervals if the truck works in extreme conditions or in rugged environments.

Introduction

ATLET SERVICE MANUAL

3.2

3.2

Service

Service inspection list 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

Mast

Fork carriage

Thrust rollers

Service inspection list

Symptom

Inspection

B Service

A Service

Service code 2102

Chain tensioning

By hand

X

X

Damage

Visual

X

X

Damage, chain bolt

Visual, tools

X

X

Damage, chain bolt mounting

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, damage, angle

Visual

X

X

Wear, play

Visual, tools

X

X

Locking, damage

Visual, tools

X

X

X

2101

X

2104

2103, 2107

ATLET SERVICE MANUAL

3.4

Service

3.2.3

Drive unit Table 3.3 Drive unit

Inspection points Gearbox

Symptom

Inspection

B Service

A Service

Service code 3001, 3006, 3101, 3107

Oil level

Visual, filling

X

X

Oil leakage

Visual, tools

X

X

Function, noise

Listen, tool

X

X

Cable connections

Visual, tools

X

X

Arc over

Visual, tools

X

X

Carbon brush wear

Visual, tools

X

X

Carbon brush springs

Visual

X

X

Commutator

Visual, tools

X

X

Noise

Listen, tool

X

X

Damage, wear

Visual

X

X

Attachment, play

Visual, tools

X

X

Sliding bearing

Noise

Listen, lubricate

X

X

3103

Drive shaft

Noise

Listen, tool

X

X

3104

Gear

Noise

Listen, tool

X

X

3102, 3106

Drive motor

Drive wheel

ATLET SERVICE MANUAL

7028, 7113, 7039, 7027, 7112

3002, 3005

Service inspection list

Service

3.2.4

3.5

Steering Table 3.4 Steering

Inspection points

Symptom

Inspection

B Service

A Service

Service code

X

4104 7118

Gear

Noise

Listen, lubricate

Servo motor

Attachment

Visual, tools

X

X

Carbon brush wear

Visual, tools

X

X

Attachment

Visual, tools

X

X

Damage, wear

Visual, function test, tools

X

X

Damage, attachment

Visual, tools

X

X

Function

By hand

X

X

B Service

A Service

Service code

Steering wheel/ wheel spinner

3.2.5

4101

Brake Table 3.5 Brake

Inspection points

Symptom

Inspection

Braking force

Malfunction

Function test, tools

X

X

5101

Parking brake

Malfunction

Function test, tools

X

X

5102

Brake disc

Wear

Visual, tools

X

X

5104

Play adjustment

Malfunction

Function test, visual, tools

X

X

Service inspection list

ATLET SERVICE MANUAL

3.6

Service

3.2.6

Hydraulic system Table 3.6 Hydraulic system

Inspection points Hydraulic tank

Symptom

Inspection

B Service

A Service

Service code 6101

Oil level

Visual, filling

X

X

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

Cylinders

Hoses

Hydraulic pump

Spool valve

ATLET SERVICE MANUAL

X

6106

X

6109

X

6103

X

Service inspection list

Service

3.2.7

3.7

Electrical system Electrical system

Inspection points Contactors

Symptom

Inspection

B Service

A Service

Service code 7107

Malfunction

Visual, tools, replace

X

X

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

Key switch, warning light

Malfunction

Visual, tools

X

X

7105

Load control, warning light

Malfunction

Visual, tools

X

X

7105

Battery

Service inspection list

7101

X

ATLET SERVICE MANUAL

3.8

3.3

Service

Code explanations 0

3.3.1

Chassis Chassis Code

Designation

Check

Refer to

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, hydrometer and battery water bottle

ATLET SERVICE MANUAL

1

4

Code explanations

Service

3.3.2

3.9

Mast 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, 6

2107

Rollers in fork carriage

Washers, wear. Lubrication of roller surfaces.

1

3.3.3

Drive unit 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, 1

3103

Sliding bearing

Noise, lubrication

3105

Drive wheel/nuts

Wear, damage, clean, nuts.

3.3.4

5

Steering Steering Code

Code explanations

Designation

Check

Refer to

4101

Flexi wheel, steering wheel/ wheel spinner

Attachment, rotation

7

4102

Steering shaft joint

Play, lubrication.

7

4104

Sprocket

Shaft locking, lubrication

4105

Steering chains

Play, lubrication

7

ATLET SERVICE MANUAL

3.10

Service

3.3.5

Brake unit Brake unit Code

Designation

Check

5101

Braking force

Braking distance.

5102

Parking brake

Function, cable connections

5104

Brake shoes

Friction surface > min level 3 mm.

3.3.6

Refer to 11

11

Hydraulic system Hydraulic system Code

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, 1

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

ATLET SERVICE MANUAL

8

Code explanations

Service

3.3.7

3.11

Electrical system Electrical system Code

Code explanations

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

Key switch/ 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

10

10

ATLET SERVICE MANUAL

3.12

ATLET SERVICE MANUAL

Service

Code explanations

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2001A

Chassis

4.1 Introduction ...................................................................................................................4.1 4.2 Replacing the load wheel .............................................................................................4.2

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Chassis

4.1

Edition 2001A

4 Chassis 4.1

Introduction 0

The chassis on OP trucks is of a modern type with a welded frame forming a base for different types of machine housings bolted to the frame.

The mast and machine housing are bolted together. The upper attachment consists of a joint, which enables the mast to be pivoted down to a horizontal position, see section 6. This unique feature is a big advantage when transporting trucks with high lifting heights.

Standard tightening torques are used for all the bolted joints, see section 1, unless otherwise stated.

Introduction

ATLET SERVICE MANUAL

4.2

4.2

Chassis

Replacing the load wheel 0

1

Lift up the truck by placing a jack under the chassis base at the drive wheel, see Figure 4.1, "Lift up the truck".

2. Place blocks (max 100 mm high) under the straddle legs, see Figure 4.2, "Place blocks under the straddle legs".

3. Lower the jack so that the truck tilts over and the load wheel leaves the floor, see Figure 4.3, "Lower the jack".

4. Remove the bolt, pos. 52, Figure 4.4, "Remove the bolt" and drive out the shaft, pos. 50.

5. Remove the wheel bearings.

6. Press the bearings in the wheel.

7. Check that the shaft and holes in the straddle leg are not damaged. Replace or repair anything that is damaged.

8. Lubricate the shaft, bearings and holes in the straddle legs with oil or a thinbodied rust inhibitor.

9. Fit the parts, not forgetting the spacers. When the shaft is pressed in place, check that the hole for the retaining bolt, pos. 52, is centred with the hole in the straddle leg.

10. Fit the lock bolt, lift up the truck, and remove the blocks.

11. Lower down the truck, and test drive.

SM 156.1

Figure 4.1 Lift up the truck

ATLET SERVICE MANUAL

Replacing the load wheel

Chassis

4.3

SM 157.1

Figure 4.2 Place blocks under the straddle legs

SM 158.1

Figure 4.3 Lower the jack

51

50

52

66

66

65

PA 180.1

Figure 4.4 Remove the bolt

Replacing the load wheel

ATLET SERVICE MANUAL

4.4

ATLET SERVICE MANUAL

Chassis

Replacing the load wheel

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2001A

Drive unit

5.1 Introduction ...................................................................................................................5.1 5.2 Dismantling, assembling the drive unit ......................................................................5.2 5.3 Drive motor, general instructions ................................................................................5.3 5.3.1 Storage of machines and motors ....................................................................5.3 5.3.2 First service .....................................................................................................5.3 5.3.3 Preventive maintenance ..................................................................................5.3 5.3.4 Dismantling, assembling the motor .................................................................5.4 5.4 Reconditioning the motor ............................................................................................5.6 5.4.1 Brush holders ..................................................................................................5.6 5.4.2 Motor bearings ................................................................................................5.6 5.4.3 Overhaul of 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 .........................................................................................................5.8 5.5 Insulation test ................................................................................................................5.9 5.6 Gearbox .......................................................................................................................5.10 5.6.1 First service ...................................................................................................5.10 5.6.2 Preventive maintenance ................................................................................5.10 5.7 Replacing the gears in the gearbox .......................................................................... 5.11 5.8 Replacing the drive wheel ..........................................................................................5.13 5.9 Replacing the drive shaft seal ...................................................................................5.14 5.10 Trouble shooting chart .............................................................................................5.15 ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Drive unit

5.1

Edition 2001A

5 Drive unit 00000000

5.1

Introduction The drive unit is mounted in one unit, consisting of brake (pos. 1, Figure 5.1), drive motor (pos. 2), gearbox (pos. 3) and drive wheel (pos. 5). For technical data regarding component parts, see section 1.

1

4

6

2

3

pB 180.1

5

Figure 5.1 Drive unit

Introduction

ATLET SERVICE MANUAL

5.2

5.2

Drive unit

Dismantling, assembling the drive unit 1 2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Pull out the battery plug, and remove the machine housing’s plastic cover.

Loosen the wheel nuts (do not remove).

Release the brake and drive motor cable.

Dismantle the brake.

Lift up the truck with a reliable lifting device, and secure with blocks under the chassis base, see section 1.

Drain off the oil.

Remove the retaining bolts for the mounting plate, see pos. 6 figure 5.1.

Attach a lifting device round the drive motor.

Lift out the complete drive unit from the truck and place in a clean and protected place.

Loosen the bolts between the gearbox and motor, and lift out the motor.

Remove the bolts holding the gearbox at the mounting plate.

Assemble in the reverse order.

Check the play on the brake, see section 11.

The specified tightening torque and the tensile grade of the bolts must be taken into consideration when fitting the drive unit in the machine housing. If not specified, see section 1.7 for standard tightening torque.

ATLET SERVICE MANUAL

Dismantling, assembling the drive unit

Drive unit

5.3

5.3

Drive motor, general instructions 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 of machines and motors

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 protective paper that emits gas, or the like, as well as using a moisture absorbing material, e.g. silicon gel.

5.3.2

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 no abnormal vibrations are experienced while running.

• Check that the carbon brushes are evenly worn and run easily in their holders.

5.3.3

Preventive maintenance

This is implemented in accordance with the recommended intervals 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.

• Check carbon brush wear. For minimum permitted length, see table. To replace, see section 5.3.3, Commutator and replacing the carbon brushes.

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.

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

• 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 must not be less than 24 kOhm. • Listen for noise from the bearings when the motor is run. Check that it does not vibrate abnormally.

Drive motor, general instructions

ATLET SERVICE MANUAL

5.4

Drive unit

• Blow clean the motor using dry compressed air, or clean with a vacuum cleaner.

A special cleaning fluid 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.

5.3.4

Dismantling, assembling the motor

• Remove the cables to the electric brake and electric motor, and note the cable markings to simplify refitting.

• Loosen the screws, pos. 39 figure 5.2.

• Carefully lift out the motor from the gearbox, so that the gears are not damaged.

• For repairs or reconditioning of the motor, see section 5.3 “Reconditioning the motor”.

• Check/replace the sealing ring, pos. 36 figure 5.3.

• Assemble in the reverse order.

39

1 2

37

38 36

3 21 22 20

18 19

23 4

20

25 34

5

26

35

27

6

12

30 7 11

8 24

30 31

13 14 15

10

32 33

9 28

29

16 pB 181.1

17

Figure 5.2 Drive unit

ATLET SERVICE MANUAL

Drive motor, general instructions

Drive unit

5.5

29

2 30

4 1

8

5

7

3 6

11

12 9

10

13

16

14 15

18 31

17 20

19

32

21 38

22 23 39

24 33

34 25 35 37 26

27 28

36

B 182.1

Figure 5.3 Drive motor

Drive motor, general instructions

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 then be dismantled from the drive unit. 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.

Important!

The seal, pos. 33 figure 5.3, should always be replaced during reconditioning.

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. Remove the brush holders if they are burned.

5.4.2

Motor bearings

Motor bearings should always be replaced when renovating the motor, or after max 5000 hours of operation, or alternatively 5 years, to guarantee reliability. Always use Atlet original parts! The bearings do not need to be lubricated between their replacement intervals.

5.4.3

Overhaul of commutator and replacing the carbon brushes

The armature is cleaned from dust and dirt. The commutator 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!

The commutator must not be treated with emery cloth or filed.

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.

Treating the commutator with sandstone for rapid trimming of the carbon brushes is not recommended for this motor. After changing the brushes it is important not to load the motor 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 / commutator diameter

Dimension

Carbon brush length, new brush

30.5 mm

Worn length

15.5 mm

Consumed at length

15.0 mm

Commutator diameter, new

60.0 mm

The commutator should be replaced when the diameter is

57.5 mm

After turning the commutator:

Re-turning Ovality, fixed dimension from bearing points

Max 0.03 mm

Permitted diameter of commutator

See table above.

Segment displacement

Max 0.02 mm

Keyway slotting depth

0.6 mm (see figure 5.4)

Segment breaking

R = 0.2 mm

The carbon brushes can be considered to be worn in when the running surface amounts to approx. 40%. (See figure 5.5)

SM O57.1

Figure 5.4

Reconditioning the motor

ATLET SERVICE MANUAL

5.8

Drive unit

40 % SM 163.1

Figure 5.5

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 state of charge, 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. short-circuits.

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 motor speed is noticed.

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

• Continuous driving at extremely long rates 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.

5.4.6

Assembly

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

ATLET SERVICE MANUAL

Reconditioning the motor

Drive unit

5.5

5.9

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 on machines, not persons!

Insulation test

Routines for insulation testing of all truck models.

1 Take out the insulation measuring instrument.

2. Set the test voltage to 100 volt.

3. 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 and contactors to these before doing the test.

4. 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.

5. 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).

6. Leave the earth lead in the chassis and connect the other lead to the electrical panel plug’s negative terminal. After this repeat point 5.

7. 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).

8. 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

5.10

5.6

Drive unit

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 Drain the oil from the gearbox.

2. 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!

Remember 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.

ATLET SERVICE MANUAL

Gearbox

Drive unit

5.7

5.11

Replacing the gears in the gearbox 0

1 2.

3.

4.

5.

6.

Dismantle the gearbox as shown in section see section 5.2.

Remove the steering bearing, pos. 3 Figure 5.6.

Lock the drive shaft and remove the nut, pos. 18, on the pinion shaft, pos. 23.

Remove the gear wheel from the pinion shaft.

Remove the gear wheel from the drive motor by means of an extraction tool.

Fit new gear wheels.

Important!

The gear wheels are replaced in pairs!

7. Fit new lock nuts on the shafts.

8. Lock the drive shaft, apply Loctite 207 on the pinion shaft threads, and tighten the pinion shaft nut to the specified torque of 210 Nm. 9. Tighten the nut on the motor gear. Torque 35 Nm. 10. Clean the surfaces between the steering bearing and bearing housing and fit new liquid gasket.

11. Assemble the housing and gearbox.

12. Assembly in truck, see section 5.1.

Important!

Remember to fill the gearbox with oil before starting up. The oil can be filled before the drive motor is assembled on the gearbox. To ensure 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.

Replacing the gears in the gearbox

ATLET SERVICE MANUAL

5.12

Drive unit

39

1 2

37

38 36

3 21 22 20

18 19

23 4

20

25 34

5

26

35

27

6

12

30 7 11

8 24

30 31

13 14 15

10

32 33

9 28

29

16 pB 181.1

17

Figure 5.6 Drive unit

ATLET SERVICE MANUAL

Replacing the gears in the gearbox

Drive unit

5.8

5.13

Replacing the drive wheel 1 2.

3.

4.

5.

6.

7.

Loosen the drive wheel nuts, without removing them.

Lift up the machine, secure with blocks.

Lower the machine on the blocks.

Remove the wheel bolts and lift out the wheel.

Fit the new wheel, and tighten the nuts by hand.

Lift up and remove the blocks, and lower the machine onto the floor.

Tighten the wheel nuts to the prescribed tightening torque 135 Nm.

Replacing the drive wheel

ATLET SERVICE MANUAL

5.14

5.9

Drive unit

Replacing the drive shaft seal 1 2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

Lift up the machine, and secure with blocks.

Dismantle the drive wheel.

Drain the oil from the gearbox, pos. 33 figure 5.2.

Dismantle the drive unit from the truck as shown in section 5.1.

Remove the cover, pos. 29.

Loosen the screws, pos. 27, holding the crown wheel halfway, and drive out the shaft towards the drive wheel side.

The screws can be unscrewed fully when the crown wheel and bearing have come free from the shaft. The shaft is pulled out from the drive wheel side.

Arrange the parts in the order they were dismantled to avoid confusion.

Remove the roller bearing closest to the seal by tapping the shaft end against a block of hard wood. Sometimes it is easier to remove the bearing if you insert a sharp object between the inner ring of the bearing and the flank of the shaft. Any burrs on the shaft must be removed before refitting.

Carefully clean the seat for the seal in the gear housing. When assembling, the first bearing, pos. 12, is placed on the drive wheel side.

Fit the safety ring, pos. 9, and the seal, pos. 13, in position. Ensure that it sits correctly.

Fit the guard, pos. 19, and then carefully press in the drive shaft, pos. 14.

Now assemble the crown wheel and bearing as shown in the figure. Start with the spacer.

Apply Loctite 207 to the shaft threads and screw together the complete drive shaft assembly with the washer, pos. 26, and screw, pos. 27. Tighten the screw to the specified torque.

Fit the cover, pos. 29. Remember that the drain hole should be the lowest point. Use a new gasket, pos. 28. Screw in the oil drain plug, with a new copper washer.

Fill with hypoid oil. See the table of recommended oils and oil volumes, section 1.

ATLET SERVICE MANUAL

Replacing the drive shaft seal

Drive unit

5.10

5.15

Trouble shooting chart Table 5.2 Symptom

Cause

Action

Smell of burning

Worn carbon brushes / commutator

Replace carbon brushes / turn commutator

Rattling noise / vibrations

Gear wheel breakdown

Renovate gearbox

Traces of oil under truck

Leaking drive shaft seal

Replace seal / check venting valve, pos, 37 figure 5.2.

(The drive motor must be dismantled first.)

Machine is heavy to steer

Dirt in steering bearing, or lack of grease

Lubricate / replace bearing

Machine jumps when driving, or wheel squeaks

Drive wheel worn, tread loose or out of round

Replace drive wheel

Trouble shooting chart

ATLET SERVICE MANUAL

5.16

ATLET SERVICE MANUAL

Drive unit

Trouble shooting chart

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2007A

Mast

6.1 Introduction ...................................................................................................................6.1 6.2 Erecting the mast ..........................................................................................................6.2 6.3 Adjusting the mast ........................................................................................................6.6 6.3.1 Adjusting the mast top .....................................................................................6.6 6.3.1 Adjusting the side thrust in mast .....................................................................6.6 6.4 Dismantling and assembling the mast, general .........................................................6.7 6.5 Dismantling the driver’s platform ................................................................................6.8 6.6 Dismantling the inner mast ........................................................................................6.10 6.7 Lift chains .................................................................................................................... 6.11 6.7.1 Adjusting ....................................................................................................... 6.11 6.7.2 Adjusting the chain tension sensor ............................................................... 6.11 6.7.3 Regular maintenance ....................................................................................6.12 6.7.4 Re-fitting the chains ......................................................................................6.12 6.7.5 Checking the lift chains .................................................................................6.12 6.8 Fork test .......................................................................................................................6.14 6.9 Trouble shooting chart ...............................................................................................6.16

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Mast

6.1

Edition 2007A

6 Mast 00000000

6.1

Introduction 0

There is one mast in the standard version.

Table 6.1 Designation

Description of mast

TV

Telescopic Free-view

DTFV

Double telescopic Free-view

A telescopic mast consists of an outer and inner mast, driver’s platform and lift cylinder. The driver’s platform is lifted up and down in the inner mast, which in turn moves up and down in the outer mast. The double telescopic mast has also a middle mast.

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

On OP there is an initial mast mounted on the driver’s platform, which enables an ergonomic workplace since the pallet can be lifted to a comfortable picking level.

Introduction

ATLET SERVICE MANUAL

6.2

6.2

Mast

Erecting the mast 0

OP trucks with higher lifting heights are often delivered from the factory with the mast folded down, which has to be erected after delivery to the customer.

The truck is delivered on a transport pallet and should be lifted down by an appropriate means.

Place the pallet with the truck so that: • A lifting device can be used to lift up the top end of the mast.

• A lifting device can be used to lift the truck straight up, so that the pallet can pushed out of the way after erecting the mast.

Since the mast has a low centre of gravity it must be prevented from falling out of control over its balanced position, see Figure 6.1, "Prevent the mast falling".

Warning risk of crushing SM 159.1E

Figure 6.1 Prevent the mast falling

1

Use a lifting strap with sufficient capacity, see truck’s machine plate. Attach the lifting strap round the cross stay in the top end.

Warning!

Place the lifting strap under the top end, see Figure 6.2, "Attaching lifting strap".

ATLET SERVICE MANUAL

Erecting the mast

Mast

6.3

SM 160.1

Figure 6.2 Attaching lifting strap 2.

3.

Attach a lifting strap in the back of the fork carriage or under the driver’s platform, see Figure 6.2, "Attaching lifting strap".

Attach a lifting device in each lifting strap.

Lift the top of the mast slightly to relieve the bolts holding the transport strut, Figure 6.3, "Relieving the bolts", and remove the strut.

SM 161.1

Figure 6.3 Relieving the bolts

4.

8.

Carefully lift up the top of the mast, while stretching the lifting strap attached to the back of the fork carriage/driver’s platform as the mast approaches its balanced position.

When the mast has gone over its balanced position release the strap attached to the back of the fork carriage/driver’s platform so that the mast stands straight up by virtue of its inherent weight.

Push the battery out to one side.

Fit the lower retaining bolts, pos. 24, Figure 6.4, "Retaining bolts" with nut washers, pos. 35, and new locking washers, pos. 36.

Repeat on the other side.

Erecting the mast

ATLET SERVICE MANUAL

5.

6.

7.

6.4

Mast

25

17

18

19 20

18 26 27 22 27 26

23 24

3031

32

24 34

35 3637 43 44 P2A 180.1

4546

47

Figure 6.4 Retaining bolts

Important!

The mast must be adjusted with shims, pos. 22, under the upper pivot attachment if the bolts cannot be fitted because the holes are displaced.

9. When the bolts are fitted they should be tightened alternately to the prescribed torque, see section 1.

10. Fit the strut between the machine housing and top of the mast (if so equipped). See Figure 6.5, "Fitting of strut"

ATLET SERVICE MANUAL

Erecting the mast

Mast

6.5

SMOP_060300

Figure 6.5 Fitting of strut 11. Push out the battery and remove the driver’s platform lock, which is accessible from the battery compartment, see Figure 6.6, "Dismantling the driver’s platform lock".

12. Continue to carefully lift the mast with the lifting device attached to the top of the mast, so that the pallet under the truck can be moved out of the way.

13. Carefully lower the truck to the floor and remove all the lifting devices.

14. Pack the driver’s platform lock and transport strut, and return them to: ATLET AB S-435 82 Mölnlycke SWEDEN

SM 164.1

Figure 6.6 Dismantling the driver’s platform lock

Erecting the mast

ATLET SERVICE MANUAL

6.6

6.3

Mast

Adjusting the mast 0

6.3.1

Adjusting the mast top 0

The four brass screws, pos. 1 Figure 6.7, "Adjusting screws", in the top of the outer mast are tightened until they contact. After which they are released 90°. Secure with lock nuts.

Important!

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

1

2

SMOP_060400

Figure 6.7 Adjusting screws

6.3.1

Adjusting the side thrust in mast

On the truck’s lifting system there are a number of adjusting screws to adjust the side thrust. They consist of headless cap screws with lock nuts. An example of such a screw is shown in pos. 2 in Figure 6.7, "Adjusting screws". To adjust release the nut and screw in the screw, which in turn presses a brass block against the other part of the mast. It is important to remember to lock with the nut after adjusting.

ATLET SERVICE MANUAL

Adjusting the mast

Mast

6.4

6.7

Dismantling and assembling the mast, general 0

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 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.

The following is generally applicable for all types of masts when assembling: • Check that the mast stands straight in relation to the machine housing.

• Mount the fork carriage, and check the play. Shim if necessary.

• The mast is assembled in the reverse order to dismantling.

• Play for fork carriage Lower/outer side thrust rollers and roller surfaces mast 3.0 mm Upper/inner side thrust rollers and roller surfaces mast 1.0 mm • Play for mast Side thrust rollers and roller surfaces 1.0 mm

Dismantling and assembling the mast, general

ATLET SERVICE MANUAL

6.8

6.5

Mast

Dismantling the driver’s platform 0

1 2.

3.

4.

5.

Place a pallet under the driver’s platform and lower down until the chains slacken.

Dismantle the panels and floor in the platform.

Separate the cable going over the mast to the driver’s platform at the connectors located under the plastic window in the driver’s platform.

Remove the cables and place them over the machine housing so that they will not be damaged.

Remove the hydraulic hose from the initial lift cylinder, and place it over the machine housing so that it will not be damaged.

Important!

Remember to plug the hose and cylinder to avoid unnecessary leakage!

6. Release the lift chains from the driver’s platform and place them over the machine housing.

7. Release the upper retaining bolts for the lift cylinders, see pos. 3 Figure 6.8, "Brass screws".

8. Attach a lifting strap round the inner mast’s upper cross stay, see figure 6.6, and then use an overhead crane to carefully lift the inner mast straight up until the driver’s platform is released from the mast.

Important!

Check that no microswitches have been damaged when lifting the mast straight up, they are mounted on the platform!

9. Use a pallet lifter and move the driver’s platform out of the way.

10. Assemble in the reverse order.

ATLET SERVICE MANUAL

Dismantling the driver’s platform

Mast

6.9

14

1 3

1 10

4

8

2 10

7

9

9 17

7

18 19

21 5

20

30

32

7

25

24 36

2

9

23

31

10

9

8 10

22

15

6

37

35

26 27

17 11

34 38 39 36

13

41

20 47 20 5

21 50 17 19

18

49

48 45 46

pC 180.1

Figure 6.8 Brass screws

Dismantling the driver’s platform

ATLET SERVICE MANUAL

6.10

6.6

Mast

Dismantling the inner mast 0

1 2.

3.

4.

5.

6.

7.

Dismantling the inner mast.

When the platform has been dismantled as shown in sectionsee section 6.5, "Dismantling the driver’s platform" the inner mast can be dismantled as follows: Remove the adjustment screws, pos. 22-27 Figure 6.8, "Brass screws".

Check that no cables, hoses or chains are trapped and damaged when lifting the mast.

Carefully lift the mast straight up, see Figure 6.9, "Lift the mast".

When the inner mast’s load rollers make contact with outer mast rollers, angle the inner mast towards and over the machine housing so that the load rollers are released from each other.

Lift down the inner mast to the floor, or designated place, for further work.

If the ceiling height is not sufficient: First remove the driver’s platform, fold down the mast, and carry out dismantling according to points 3-7 above.

1 2

SM 162.1

Figure 6.9 Lift the mast

ATLET SERVICE MANUAL

Dismantling the inner mast

Mast

6.7

6.11

Lift chains 0

6.7.1

Adjusting

5 2

• The mast should be lowered.

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

• Adjust the platform’s safety chain (if so equipped) so that it is somewhat slacker than the platform’s lift chains.

• Adjust the fork carriage chain so that the fork blade is 5 ± 2 mm from the ground.

SM 075.1

Figure 6.10 Fork size

6.7.2

Adjusting the chain tension sensor

After adjusting the platform’s lift chains, check that there is a clearance of a few mm between the sensor’s roller and the large ring nut. Remember to lock after adjusting.

SMOP_060200

Figure 6.11 Chain tension sensor

Lift chains

ATLET SERVICE MANUAL

6.12

Mast

6.7.3

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.

6.7.4

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.

6.7.5

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 6.12 Chain dimensions

ATLET SERVICE MANUAL

Lift chains

Mast

6.13

Table 6.2 Chain dimension (inches)

P (nominal) Pitch dimension (mm)

P (true) True pitch dimension (mm)

Measureed over 25 links New chain (mm)

Max over 25 links 2% elongation (mm)

1/2”-2*2

12.70

12.59

314.75

321.05

5/8”-4*4

15.88

15.875

396.88

404.81

3/4”-3*4

19.05

19.05

476.25

485.78

3/4”-4*4

19.05

18.91

472.75

482.21

1”-4*4

25.40

25.32

633.00

645.66

1 1/4”-4*4

31.75

31.54

788.50

804.27

1 1/2”-4*4

38.10

38.06

951.50

970.53

• Measure the height of the chain’s link plates, dimension G, see Figure 6.12.

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 6.13.

A

B

SM 169.2

Figure 6.13 Twisted pin • • • •

Lift chains

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.

ATLET SERVICE MANUAL

6.14

6.8

Mast

Fork test 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 6.14, "Straightness of the blades and shanks".

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

x x x x

SH

AN K ON T FA CE

x x x x

B LA D

E ,U

P

P E R

FA C

E

FR

Diference in height between fork arm tips

SM 020.3E

Figure 6.14 Straightness of the blades and shanks Crack formation: Check whether the forks are cracked. Check carefully around the heel and hooks. See Figure 6.15, "Crack formation".

ATLET SERVICE MANUAL

Fork test

Mast

6.15

Thickness

Shank

Tip Thickness

Hook Blade

Heel L=Length SM 021.3E

Figure 6.15 Crack formation 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: • Reading the markings on old forks.

• Measuring the blade thickness in the centre of the shank.

• 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 6.14, "Straightness of the blades and shanks".

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 6.14, "Straightness of the blades and shanks".

Fork test

ATLET SERVICE MANUAL

6.16

6.9

Mast

Trouble shooting chart

.

0

Table 6.3 Symptom

Cause

Action

The mast lowers unevenly, jumps.

No grease on the mast’s roller and slide surfaces.

Grease the roller and slide surfaces.

The mast squeaks.

No grease on the mast’s roller and slide surfaces.

Grease the roller and slide surfaces.

ATLET SERVICE MANUAL

Trouble shooting chart

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2001A

Steering

7.1 Introduction ..................................................................................................................7.1 7.2 Servo steering unit .......................................................................................................7.2 7.2.1 Functions .........................................................................................................7.2 7.2.2 Servo steering unit, settings ............................................................................7.3 7.2.3 Factory setting, electric steering .....................................................................7.5 7.2.4 Servo steering unit, diagnostics ......................................................................7.6 7.2.5 Trouble shooting ..............................................................................................7.7 7.3 Steering control ............................................................................................................7.8 7.3.1 Check tachometer ...........................................................................................7.8 7.3.2 Replacing the tachometer ...............................................................................7.8 7.4 Steering servo motor ..................................................................................................7.10 7.4.1 Steering servo motor, replacing carbon brushes ...........................................7.10 7.4.2 Replacing the steering servo motor ..............................................................7.10

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Steering

7.1

Edition 2001A

7 Steering 00000000

7.1

Introduction The steering movement is transferred completely electronically, without mechanical connection between the steering wheel, steering controller unit and steering servo motor. A monitoring system is built into the steering controller unit, which stops the truck if an electrical fault occurs in the steering system.

2

1

3

D 180.1

Figure 7.1 Steering – overview

Introduction

ATLET SERVICE MANUAL

7.2

7.2

Steering

Servo steering unit 0

7.2.1

Functions

RE1 RELAY

+ 1

K2

2

3

4

5

6

7

OFF

M1

M2

8

9 10

11 12 13

SW1 1 2 3 4 5 6 7 8

1

ON

2

LIN

3

LIN

4

ERROR

5

ERROR

K1

SM 033.1

Figure 7.2 Servo steering unit

Switch function (dipswitch) No. 1

Function Current limiting

2 3

IR compensation

4 5

Sensitivity

6 7 8

ATLET SERVICE MANUAL

Servo steering unit

Steering

7.3

Indicator lamp LED No. 1

Everything OK

2

End position

3

End position

4

Fault

5

Fault

7.2.2 1

Indicates the following when on

Servo steering unit, settings

Current limiting to the motor (regulates the steering 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 Table 7.1.

Table 7.1 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 limiting 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 Table 7.2

Servo steering unit

ATLET SERVICE MANUAL

7.4

Steering

Table 7.2 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/steering servo motor): The sensitivity can be set to 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 progressive steering. This means the sensitivity automatically increases with rapid steering wheel movements.

Settings in accordance with Table 7.3

ATLET SERVICE MANUAL

Servo steering unit

Steering

7.5

Table 7.3 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)

7.2.3

Factory setting, electric steering Table 7.4 Switch

Servo steering unit

1

ON

2

OFF

3

OFF

4

ON

5

ON

6

OFF

7

ON

8

ON

ATLET SERVICE MANUAL

7.6

Steering

7.2.4

Servo steering unit, diagnostics Table 7.5 Control connection 13 pins No.

1. In

Signal 24V

2.

Description Start/stop, internal supply Not connected

3. Out

Open

Fault 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 fault indicating

10.

Not connected

11. In

24V

Positive direction

12. Out

Fault code no. 2

13.

Not connected

Table 7.6 Power connection 4 pins In/out

Signal

Description

+ In

24V

Battery voltage +

- In

0V

Battery voltage -

M1 Out

Motor connection + / -

M2 Out

Motor connection - / +

ATLET SERVICE MANUAL

Servo steering unit

Steering

7.2.5

7.7

Trouble shooting Table 7.7

LED 1 Green

Servo steering unit

LED 2 Red

LED 3 Red

LED 4 Red

LED 5 Red

Indicates

Action

—

—

—

—

—

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 steering servo motor, fuses and contactors. If these are OK, replace the steering servo motor or steering unit.

ON

—

—

ON

ON

Fault in steering unit

Replace steering unit.

ATLET SERVICE MANUAL

7.8

7.3

Steering

Steering control 0

7.3.1

Check tachometer

The tachometer is checked by measuring the resistance with a digital measuring instrument. The actual check is best made in two steps.

Step 1: Measure the resistance between pin 3 & 4 in the connector X56, the steering control’s large connector for connection to the platform.

If you obtain a value that significantly deviates from 45.8 Ohm you should continue to step 2.

Step 2: Measure the resistance directly on the tachometer’s connector, X54.

1 Park the truck in a safe place where it cannot do any damage to the surroundings or yourself.

2. Switch off the main power.

3. Release the four socket head cap screws holding the cover.

4. Turn up the cover and remove the cables to the tachometer.

5. Connect the instrument to the tachometer.

6. Read-off the value, it should be approx. 45.8 Ohm. 7. If the resistance is infinite there is a break in the tachometer and it should be replaced, which should also give a fault code on the control unit.

pD 42.2

Figure 7.3 Tachometer

7.3.2 1 2.

3.

Replacing the tachometer

Park the truck in a safe place where it cannot do any damage to the surroundings or yourself.

Switch off the main power.

Release the four socket head cap screws holding the cover.

ATLET SERVICE MANUAL

Steering control

Steering

4.

5.

6.

7.

7.9

Turn up the cover. To improve access it is possible to cut the cable ties supporting the cable, but first make sure there are new ones which can be fitted afterwards.

Loosen the nuts holding the tachometer’s attachment plate to the cover.

Release the attachment from the tachometer by unscrewing the four slotted head screws.

Fit the attachment plate on the new tachometer and replace in the reverse order.

SMOP_070100

Figure 7.4 Inside of the control unit

Steering control

ATLET SERVICE MANUAL

7.10

7.4

Steering

Steering servo motor 0

The functions of the motor should be checked every 500 hours of operation. The motor is appropriately cleaned with compressed air.

Warning!

Do not inhale the dust.

If the collector has gone out of round, or there is excessive sparking during operation, it can be re-turned. The service-life of the bearings depend on the type of operation. If one of the bearings has been damaged, they should both be replaced.

Lubrication is not possible since they are of the sealed type.

Table 7.8 Min Carbon brush length

11 mm

Collector diameter

42,0

7.4.1 1 2.

3.

Max

45,6

Steering servo motor, replacing carbon brushes

Remove the cover, pos. 1 see Figure 7.5.

Remove the cables to the brush holders, pos. 2.

Pry out the brush holders, pos. 3, by moving them to the left so that the tensioning tab is pressed in, and pull them out as a complete unit.

1

2 3

SM 165.1

Figure 7.5 Steering servo motor

7.4.2 1 2.

Replacing the steering servo motor

Loosen the cables to the motor.

Loosen the motor by unscrewing the four socket head cap screws.

ATLET SERVICE MANUAL

Steering servo motor

Steering

3.

4.

5.

7.11

Carefully lift out the motor and transfer the gear to the new motor.

Assemble in the reverse order.

Remember that the steering servo motor must not be placed butt to butt with the bottom plate.

Important!

Remember to lock with the screws with Loctite.

SMOP_070300

Figure 7.6 Steering servo motor attachments

Steering servo motor

ATLET SERVICE MANUAL

7.12

ATLET SERVICE MANUAL

Steering

Steering servo motor

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2004B

Hydraulic system

8.1 Introduction ...................................................................................................................8.1 8.2 Replacement of the hydraulic filter .............................................................................8.2 8.3 Draining the tank ...........................................................................................................8.3 8.3.1 Checking the hydraulic oil level .......................................................................8.4 8.4 Hose rupture valve ........................................................................................................8.5 8.4.1 Hose rupture valve, dismantling and assembling ............................................8.5 8.4.2 Setting the hose rupture valve ........................................................................8.6 8.5 Hydraulic valve, general ...............................................................................................8.7 8.5.1 Functional description, hydraulic valve ...........................................................8.7 8.5.2 Function of the coils ........................................................................................8.8 8.5.3 Checking the lowering speed ..........................................................................8.9 8.5.4 Adjusting the lifting-lowering function from OP-1429 ......................................8.9 8.5.5 Adjusting the regulator, electric valve to OP-1429 ........................................8.10 8.5.6 Adjusting the hydraulic lowering speed valve in the hydraulic valve .............8.12 8.5.7 Adjusting the working pressure .....................................................................8.12 8.6 Lift motor .....................................................................................................................8.13 8.6.1 Dismantling of the lift motor OPH, OPS, OPC ...............................................8.13 8.6.2 Dismantling the lift motor OPM ......................................................................8.15 8.7 Checking the lift motor OPH ......................................................................................8.17 8.8 Hydraulic diagram .......................................................................................................8.17

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Hydraulic system

8.1

Edition 2004B

8 Hydraulic system 00000000

8.1

Introduction 0

Note!

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

The truck is equipped with separate controls for lifting/lowering of the driver’s platform and forks. They can only be operated separately since the design of the hydraulic system does not permit simultaneous movement. The control for lifting and lowering of the driver’s platform is comfortably positioned in connection with the control lever for drive.

The hydraulic valve consists of a proportional valve, which is used for lifting the platform, and an on/off valve for lifting the forks. Both valve functions are softclosing to ensure the best possible driving comfort. Pre-set electric restriction of the lowering valve is used for bottom position damping during lowering of the driver’s platform, which is actuated by a switch placed in the mast system.

Different sizes of hydraulic units are used, depending on the truck’s lifting height.

Introduction

ATLET SERVICE MANUAL

8.2

8.2

Hydraulic system

Replacement of the hydraulic filter 0

1 2.

3.

4.

5.

Loosen the cover, pos. 7 Figure 8.1, "Hydraulic tank and filter".

Lift out the filter insert, pos. 9. Support against pos. 10 if it jams.

Fit the new insert. Press home.

Fit the cover, pos. 7, (do not tighten too hard).

Replace the air filter, pos. 5.

1

7

2 3

8 5 4

9 17

18

10

19

6

11 12

20 21 22

13

23

24

pE 180.1

Figure 8.1 Hydraulic tank and filter

ATLET SERVICE MANUAL

Replacement of the hydraulic filter

Hydraulic system

8.3

8.3

Draining the tank 0

1 2.

3.

4.

5.

6.

Remove the plastic cover over the battery, pos. 3 Figure 8.2, "Tank emptying".

Lower down the forks and driver’s platform.

Relieve the system pressure.

Release the hose to the mast, pos. 28, and plug the pipe to the mast.

Bend down the hose into a can or suitable container.

Use the truck’s pump, and pump out the oil slowly and carefully. Stop before the pump runs dry, when there is a low oil level in the tank.

26 27 28

3

76

4

SM 167.1

Figure 8.2 Tank emptying

Draining the tank

ATLET SERVICE MANUAL

8.4

Hydraulic system

8.3.1 1 2.

3.

4.

5.

Checking the hydraulic oil level

Lift the driver’s platform and the initial lift to its top position.

Check that the hydraulic pump does not suck air. This can be recognised by the function in operation moving jerkily, or by an abnormal screeching noise.

If the hydraulic pump sucks air lower down all the hydraulic functions to their lower positions, remove the machine housing cover, and check the oil level in the hydraulic tank.

Fill with hydraulic oil of the grade recommended in section 1 so that the level rises a few cm, perform the “test lift” and check as above.

Repeat this procedure until a normal function is obtained.

ATLET SERVICE MANUAL

Draining the tank

Hydraulic system

8.4

8.5

Hose rupture valve 0

The hose rupture valve is mounted in the top of the lift cylinder, see pos. 14 Figure 8.3, "Hose rupture valve"

10

11 9 8 12

6

13 14 17

12 15 pF 206.1

16

Figure 8.3 Hose rupture valve

8.4.1 1 2.

3.

4.

5.

6.

Hose rupture valve

Hose rupture valve, dismantling and assembling

Lower down and relieve the hydraulic system.

Loosen the oil connection to the cylinder.

Release and remove the nipple, pos. 17 Figure 8.3, "Hose rupture valve", screwed into the cylinder.

Unscrew the hose rupture valve, pos. 14. Adjust, or replace the hose rupture valve.

Assemble in the reverse order.

Bleed the hydraulic system, and test run.

ATLET SERVICE MANUAL

8.6

Hydraulic system

8.4.2

Setting the hose rupture valve Table 8.1 Cylinder

Atlet P/N

Marking

s mm

Q l/min

Lift cylinder, outer

009185

LB3C

1,2

50

Lift cylinder, initial

009185

LB3C

0,35

20

SM 171.1

S

Figure 8.4 S dimension for hose rupture valve

ATLET SERVICE MANUAL

Hose rupture valve

Hydraulic system

8.5

8.7

Hydraulic valve, general 0

The valve has a built-in lowering speed valve for the driver’s platform, pos. 16 Figure 8.5, "Hydraulic valve", an emergency lowering valve for the driver’s platform, pos. 17, and an adjustable pressure limiting valve, pos. 18.

Important!

NOTE! The tightening torque of 60 Nm for the connecting nipples must not be exceeded.

3

16

Y3

17 Y1

18 Y4 Y2

pE 182.1

Figure 8.5 Hydraulic valve

8.5.1

Functional description, hydraulic valve

The electric proportional valve controls the truck’s lifting and lowering movements.

The pressure chamber is the heart of the hydraulic proportional valve. It is set at the factory and should NEVER be altered.

The feed restriction in the proportional valve has a stroke length limit, which can be set from outside. The stroke length limit governs the maximum lowering speed.

The pressure chamber maintains a constant pressure drop over the feed restriction in the proportional valve during lowering. This enables the lowering speed to remain constant regardless of the load, and therefore no external lowering brake valves are required.

The lifting and lowering speed is regulated by a single proportional solenoid.

Lifting function The pump supplies a pressure to the control valve, which in turn closes the pressure chamber completely. This pressure also opens the non-return valve and then continues through the open proportional valve to the lift cylinders If the lift cylinders are obstructed, have an excessive load, or if there is a fault on the proportional valve so that it does not open, the oil will return to the tank through the pressure limiting valve.

Hydraulic valve, general

ATLET SERVICE MANUAL

8.8

Hydraulic system

Lowering function The proportional valve opens to release the oil from the lift cylinders. Since the nonreturn valve is closed, the only way out for the oil is through the pressure chamber.

The flow through the pressure chamber is in turn controlled by the pressure difference over the feed restriction in the proportional valve, since the control valve does not receive pressure from the pump.

Figure 8.6 Hydraulic valve

8.5.2

Function of the coils Table 8.2 Y1

Y2

Y3

Lift forks

¤

Lower forks

¤

Lift platform Lower platform

Y4

¤ ¤

¤

¤ = Current to coil

ATLET SERVICE MANUAL

Hydraulic valve, general

Hydraulic system

8.5.3

8.9

Checking the lowering speed

When checking and adjusting the lowering speed of the driver’s platform a check is made how quickly it lowers with the load on the forks specified on the truck’s machine plate.

Check the actual lowering speed with the table below.

Table 8.3 Truck type

Lowering speed m/s

OPM, OPC, OPH, OPS

max 0.4

If the correct lowering speed cannot be achieved, the electrical signal from the control unit to the solenoid valves should be checked first, in accordance with section 8.5.4, "Adjusting the lifting-lowering function from OP-1429", or section 8.5.5, "Adjusting the regulator, electric valve to OP-1429".

The hydraulic valve is then adjusted in accordance with section 8.5.6, "Adjusting the hydraulic lowering speed valve in the hydraulic valve"

8.5.4

Adjusting the lifting-lowering function from OP1429

Before the adjustment starts, place 700 kg on the forks. Operate the truck until the hydralic oil is at working temperature. Open the machine house, lower the electrical panel. Remove the cover from the electronics box E3.

Electronics box When changing the electronics box, turn the potentiometers according to the figure.

1 2 3 4 5

SMOP_080100

START

RANGE

RANGE

CENTER

Bild 8.7 Electronics box E3

Hydraulic valve, general

ATLET SERVICE MANUAL

8.10

Hydraulic system

Start ramp: Adjust the potentiometer CENTER counter-clockwise to make the start quicker. To make the start softer, adjust the potentiometer clockwise.

Reducing the lowering speed: Adjust the potentiometer RANGE ⇑ counter-clockwise to make the stop more softer. For quicker stop, adjust the potentiometer RANGE ⇑ clockwise. The cabin must be lifted minimum 1.5m and then lovered with maximum speed. At 0.5m the speed starts to reduce.

Lowering-stop just before bottom: If the cabin stops to hard in the bottom, adjust potentiometer RANGE ⇓ counterclockwise. If the cabin movement are to slow, adjust potentiometer RANGE ⇓ clockwise.

Start and stop: For softer start and stop, adjust potentiometer START counter-clockwise. For quicker start and stop, adjust potentiometer START clockwise.

DTF-mast: The transitions between inner and outer mast are adjusted with the potentiometer R15 och R16. The potentiometers are mounted om relay K20 and K21, which are mounted behind the plastic panel in the cabin.

• Adjust R15 counter-clockwise to reduse lifting movement before the mast meets.

• Adjust R16 counter-clockwise to reduse lowering movement before the mast meets.

Important!

When the adjustments are finished you must contol the movements again because some adjustments effect others.

8.5.5 1 2.

3.

4.

5.

6.

7.

8.

9.

Adjusting the regulator, electric valve to OP-1429

Lift the drive wheel.

Pull out the control cable to contactor K3 so that it cannot be activated by mistake.

Close the gates and activate the green button.

Connect a digital instrument between pin 10 and 11 in connector X.2 (mounted in the machine housing).

Activate the lowering function and adjust with the potentiometer, located on the small card behind the panel in the driver’s platform, until a voltage of 2.9 V is obtained.

Remove one of the cables and connect an ammeter in series with the proportional valve’s coil Y2.

Actuate the lowering lever and adjust the potentiometer located in the control unit, marked “START”, until a current of 0.35 A is obtained.

Actuate the lift control, measure the current as above, and adjust the potentiometer in the control unit and marked “RANGE ⇓” until a current of 0.53A is obtained.

Refit the cable to coil Y-2.

ATLET SERVICE MANUAL

Hydraulic valve, general

Hydraulic system

8.11

10.

11.

12.

13.

Connect the digital instrument as in point 4 above.

Adjust as in point 5 above until a voltage of 3.1V is obtained.

Connect the control cable to contactor K3.

Set the start rate with the potentiometer in the control unit, marked “CENTER”, until a comfortable start rate is obtained.

14. Set the stop rate with the potentiometer in the control unit, marked “RANGE ⇑” so that the platform brakes gently and does not hit the bottom position at full speed.

15. Check that all the truck’s hydraulic functions function well, and then refit all the panels.

1 2 3 4 5

SMOP_080100

START

RANGE

RANGE

CENTER

Figure 8.8 Electronics box for hydraulic valve

The LEDs, pos. 1 to pos. 5 in Figure 8.8, are described in Table 8.4.

Hydraulic valve, general

ATLET SERVICE MANUAL

8.12

Hydraulic system

Table 8.4 LED #

Colour

Function

1

Green

Supply voltage

2

Yellow

Pump motor active

3

Yellow

Lowering valve active

4

Yellow

Proportional valve active

5

Red

On – Lift function active Off – Lift function inhibited

8.5.6

Adjusting the hydraulic lowering speed valve in the hydraulic valve

As a first step all the settings of the control unit should always be checked before a hydraulic adjustment.

See adjusting the control unit, hydraulics section 8.5.4, "Adjusting the liftinglowering function from OP-1429" or section 8.5.5, "Adjusting the regulator, electric valve to OP-1429" If the correct lowering speed has not been obtained (see section 8.5.3, "Checking the lowering speed") adjust the lowering speed valve mounted on the hydraulic valve, see pos. 16, until the correct lowering speed is obtained

8.5.7 1 2.

3.

4.

5.

Adjusting the working pressure

Place the truck’s max load on the forks (specified on the truck’s machine plate).

Unscrew the adjusting screw, pos. 18 Figure 8.5, "Hydraulic valve", two turns to the left.

At the same time as the lift function for the driver’s platform is actuated, screw in the adjusting screw until the platform begins to lift from the floor, and then screw in an additional ¼ of a turn and lock.

Finally, perform repeated lifting operations to ensure that the lifting capacity is sufficient.

Seal!

ATLET SERVICE MANUAL

Hydraulic valve, general

Hydraulic system

8.6

8.13

Lift motor 0

8.6.1 1 2.

3.

4.

5.

6.

7.

8.

Lift motor

Dismantling of the lift motor OPH, OPS, OPC

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.

Secure the mast.

Disconnect the battery.

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

Loosen the four retaining bolts, pos. 15 Figure 8.9, "OPH"(pos 29 Figure 8.10, "OPS, OPC") that hold the pump to the hydraulic motor.

Remove the bolts holding the clamp round motor.

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

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

Assemble in the reverse order.

Important!

Check that the connector, pos. 12 (OPH) or pos. 26 (OPS, OPC), is turned in the right direction and that the motor and pump journals come at 90° in relation to each other.

ATLET SERVICE MANUAL

8.14

Hydraulic system

1

27

16 17

27

28

18

20

19

21

21

26

22 24

23

25

9 11 12 13 14 31 29 36 37 38 39

31

29 31

33 32

30

34

35 15 E 33.5

Figure 8.9 OPH

ATLET SERVICE MANUAL

Lift motor

Hydraulic system

8.15

32

34 33

35 36 37

17

16 18 1

20

6 2

21

3 7

4

22 23 24

8 5

9

10

25 26 14 15 27

11 12

28

29 E 183.1

Figure 8.10 OPS, OPC

8.6.2 1 2.

3.

4.

5.

Lift motor

Dismantling the lift motor OPM

Disconnect the battery.

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

Loosen the two retaining bolts holding the pump to the motor (do not remove).

Loosen and remove the bolts holding the clamp round the motor.

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

Assemble in the reverse order.

Important!

Grease in the pump journal before fitting!

ATLET SERVICE MANUAL

8.16

Hydraulic system

38 1

37

2

23

3 4 65

7 8 24

11 12 27 13 14

29 30 31

1516 171819 33 20

34 35 36

21

E 175.1

Figure 8.11 OPM

ATLET SERVICE MANUAL

Lift motor

Hydraulic system

8.7

8.17

Checking the lift motor OPH 0

1 2.

3.

4.

5.

6.

7.

8.

8.8

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.

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.

If oil has got into the motor it should be cleaned with an electrical cleaner.

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

Check that all connections are tightened.

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

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.

Hydraulic diagram Table 8.5 Description Hydraulic diagram

Checking the lift motor OPH

Machine type OP

Reference

Document code 103424

Issue A

ATLET SERVICE MANUAL

8.20

ATLET SERVICE MANUAL

Hydraulic system

Hydraulic diagram

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2001A

Lift cylinders

9.1 Dismantling and assembling .......................................................................................9.1 9.2 Dismantling and assembling .......................................................................................9.2 9.2.1 Adjusting the lift cylinders ................................................................................9.2

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Lift cylinders

9.1

Edition 2001A

9 Lift cylinders 00000000

9.1

Dismantling and assembling 1 2.

3.

4.

5.

6.

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.

Release the retaining bolts, pos. 11, Figure 9.1(do not remove).

Lower down the cylinder to the fully retracted position.

Loosen, disconnect, and plug the oil pipe.

Remove the retaining bolt, pos. 11.

Lift out the cylinder.

Assemble in the reverse order.

3 2 10

X X X X X

11

9

A

8

5

12

6

1

13 14

17 4

12 15 16 F 206.1

Figure 9.1 Lift cylinder

Dismantling and assembling

ATLET SERVICE MANUAL

9.2

9.2

Lift cylinders

Dismantling and assembling 0

1

2.

3.

Note how far the adjusting nut, pos. 10 Figure 9.1, is screwed into the piston rod end (required when fitting).

Unscrew the adjusting nut, pos. 10.

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. 6, and remove it, and take out the piston rod, pos. 5.

6. Remove the sealing rings and guides, pos. 8 and 9, from the top nut.

7. Remove the guides, pos. 4, and locking wire, pos. 17, from the piston rod.

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

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

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

9.2.1 1 2.

3.

Adjusting the lift cylinders

Lower down the mast to its bottom position.

Adjust dimension A so that it is 1-2 mm on both sides by screwing the nut, pos. 3, Figure 9.2, "Adjusting the lift cylinders".

Lift to maximum height and check that both lift cylinders are equally adjusted.

2

1

A

3

SMOP_060100

Figure 9.2 Adjusting the lift cylinders

ATLET SERVICE MANUAL

Dismantling and assembling

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2004B

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 10.4 Electrical panel ..........................................................................................................10.4 10.4.1 Front of the electrical panel .........................................................................10.4 10.4.2 Back of the electrical panel .........................................................................10.5 10.5 Switches and sensors ..............................................................................................10.6 10.5.1 Replacing the 1.2 metre switch ...................................................................10.6 10.5.2 Replacing the magnet switch ......................................................................10.7 10.5.3 Replacing the gate contact switch ...............................................................10.7 10.5.4 Optical aisle sensor, rail guidance ...............................................................10.8 10.6 Transistor system Curtis 1243 .................................................................................10.9 10.6.1 Technical description ...................................................................................10.9 10.6.2 Hand terminal ............................................................................................ 10.12 10.6.3 Special program ........................................................................................10.14 10.6.4 Special Diagnostics ................................................................................... 10.14 10.6.5 Programming ............................................................................................. 10.14 10.6.6 Adjustment instructions .............................................................................10.15 10.6.7 Function and Installation checking ............................................................10.19 10.6.8 Trouble shooting by means of LED ...........................................................10.21 10.6.9 Trouble shooting by means of Test menu .................................................10.23 ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

10.6.10 Specifications .......................................................................................... 10.24 10.7 Regulator, electric valve ........................................................................................ 10.25 10.8 Wiring diagram ....................................................................................................... 10.26

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Electrical system

10.1

Edition 2004B

10 Electrical system 00000000

10.1

Safety procedures 0

• Working 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.

• It is important that the correct polarity is connected to the regulator’s main supply via the battery plug.

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 of 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

See section 5, Drive unit

Drive motor

ATLET SERVICE MANUAL

10.4

10.4

Electrical system

Electrical panel 0

10.4.1

Front of the electrical panel

1

2

3

9 4 8 7 5

6 SMOP_100200

Figure 10.1 Front of distribution board Table 10.1 Position

Designation

1

Control fuses

2

Steering regulator

3

Contactor, drive motor

4

Drive regulator

5

G terminal

6

Emergency contactor

7

Main fuse, drive motor

8

Main fuse, hydraulic unit

9

Contactor, hydraulic unit

ATLET SERVICE MANUAL

Electrical panel

Electrical system

10.4.2

10.5

Back of the electrical panel

2

1

3 10 4 5 6

9

7

8

SMOP_100300

Figure 10.2 Back of the electrical panel Table 10.2 Position

Description

1

Control fuses (same as pos. 1 in Figure 10.1)

2

K5 – Relay, steering

3

K8 – Relay, supply to electronic hydraulic valve K9 – Relay, initial lift K10 – Relay, initial lowering

Electrical panel

4

Resistor for steering

5

K4 – Relay, key

6

K6 – Relay, brake

7

K7 – Relay, aisle

8

Horn

9

Cooling fan

10

Regulator, electric valve

ATLET SERVICE MANUAL

10.6

10.5

Electrical system

Switches and sensors 0

There are a number of switches and sensors placed in the platform. Exactly which are fitted on respective trucks depends on the version and equipment, but certain are standard and will always be included.

1.2 metre switch This is a mechanical sensor which registers when the platform is more than 1.2 metres over the ground. This signal then controls which drive mode the truck should be in. Further information on drive modes and their variants can be found in the SEPEX section. On certain variants of the high-lifting models there is also a sensor for 6 metres.

Magnetic switch There are magnets at the top and bottom. They ensure soft damping in the top and bottom positions.

Gate contact switch These sensors ensure that the gates are closed before lifting or driving can be started.

10.5.1 1 2.

3.

4.

5.

6.

7.

Replacing the 1.2 metre switch

Lower the platform to the bottom position.

Unscrew the three screws holding the cover plate on the side of the platform and on one edge of the Plexiglass sheet.

Remove the drive controllers.

Remove the controller attachments.

Release the connector attachments for the controllers from the panel.

Release the panel and carefully remove it.

Release the switch and move the cable to the new one.

Important!

Check the position of the switch arm before refitting the panels, see Figure 10.3, "1.2 metre switch and magnetic switch.".

ATLET SERVICE MANUAL

Switches and sensors

Electrical system

10.7

SMOP_100100

Figure 10.3 1.2 metre switch and magnetic switch.

10.5.2 1 2.

3.

4.

5.

6.

7.

Lower the platform to the bottom position.

Unscrew the three screws holding the cover plate on the side of the platform and on one edge of the Plexiglass sheet.

Remove the drive controllers.

Remove the controller attachments.

Release the connector attachments for the controllers from the panel.

Release the panel and carefully remove it.

Release the switch and move the cable to the new one.

10.5.3 1 2.

3.

Switches and sensors

Replacing the magnet switch

Replacing the gate contact switch

Lower the platform to the bottom position.

Unscrew the three screws holding the cover plate on the side of the platform and on one edge of the Plexiglass sheet.

Release the switch and move the cable to the new one.

ATLET SERVICE MANUAL

10.8

Electrical system

SMOP_100400

Figure 10.4 Gate contact switch

10.5.4

Optical aisle sensor, rail guidance

There are two versions of the optical aisle sensor. The new version has increased, adjustable, sensing distance.

The part number remains the same as before and the new sensor is totally compatible with the old one. The new sensor can replace an old one without modification.

Pos

Designation

A

Sensor

B

Sensitivity adjustment screw

B A

To identify the difference between old and new sensors see table below.

Production Date

Marking on sensor

< October 14, 2002 > October 14, 2002

BSC4 BSC6

ATLET SERVICE MANUAL

Maximum operating distance 200 mm 400 mm

Switches and sensors

Electrical system

10.6

10.9

Transistor system Curtis 1243 0

Curtis 1243 is a system to regulate the speed on separately magnetised DC motors.

The electric brake is only used in emergency situations and as a parking brake. The main brake (motor brake) is controlled by the speed controller. When reversing and reducing the speed the kinetic energy is transferred to charge the battery.

The regulator controls a “main” contactor, which closes the plus supply to the drive motor. This is always applied when the machine is on and the system does not indicate any faults. If a fault is detected by the regulator the contactor opens, and driving is then impossible.

The power unit is based on MOSFET technology.

The system pulses at a frequency of 15 kHz. This means that it lies over the normally audible frequency range for people, and therefore the system is practically noiseless.

There are exceptions to the high pulse frequency: The system can withstand temperatures down to minus 40 degrees, but to reduce the strain on the capacitors below minus 25 degrees the current capacity is reduced.

In order that this will be noticed the system pulses at 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 for adjustment work and trouble shooting.

The system is protected from overvoltage and undervoltage, including high and low temperatures.

10.6.1

Technical description

A separately magnetised drive system consists of a DC motor with separate windings for armature and field, and a regulator that controls the windings individually.

The advantage in comparison with a series-wound system is that the motor is enabled to work with its optimum efficiency in all operating situations.

When a powerful torque is required, e.g. during reversing or acceleration, the regulator can provide a high current to the field winding. When a high speed is required the current can also be reduced. During normal regulation the voltage varies to the motor’s armature winding in the supply circuit.

A typical characteristic of a separate magnetised system is little difference in the speed of an empty and a loaded truck.

Transistor system Curtis 1243

ATLET SERVICE MANUAL

10.10

Electrical system

The motor’s direction of rotation is controlled by the direction of the current in the field winding by means of the regulator; no directional contactors are necessary. A safety contactor is, however, required.

Since the field parameters are the ones that vary most in relation to the previous series-wound motor, these are described below: General: The field current is controlled by a number of different parameters. It is mainly controlled by the magnitude of the armature current, and a higher armature current produces a higher field current.

There are a number of possible adjustments to vary the relationship between armature current and field current, as shown below.

Functions of the Hand terminal “FIELD MIN” adjusts the minimum current to the field winding.

The value of the field current sets the truck’s top speed. A lower field current produces a higher top speed.

Warning!

It is absolutely forbidden to adjust the parameter “FIELD MIN” to a value that produces a higher top speed than 9.0 km/hour. “FIELD MIN” must not be adjusted without checking the top speed after adjusting.

“FIELD MAX” limits the maximum current to the field winding.

“FIELD MAP START” defines the armature current value where the field current begins to increase from the “FIELD MIN” value.

Before adjusting “FIELD MAP START”, the “FIELD MIN” and “FIELD MAX” should be adjusted.

The “FIELD MAP START” value should be adjusted to a current value just over the armature current that can be measured with the Hand terminal when the truck has reached top speed with full load.

This produces the minimum difference in speed between an empty and a loaded truck.

With “FIELD MAP” it is possible to adjust a breaking point on the curve, which describes the relationship between the armature current and field current.

ATLET SERVICE MANUAL

Transistor system Curtis 1243

Electrical system

10.11

Field Current

A higher value produces a higher speed during gradient climbing, while a lower value produces more rapid acceleration.

Field Max

Field Map 50%

Field Min 0

0

Field Map Start

Field Map Midpoint

100%

Field Current

Armature Current

Field Max

Field Map 20% Field Min 0

SM 168.1

0

Field Map Start

Field Map Midpoint

100%

Armature Current

Figure 10.5 The “QUICK START” function is used if you want to shorten the set acceleration delay by means of a rapid increase in the throttle by a factor that “QUICK START” is set to.

Example: If the “ACCELERATION DELAY” is set to 3.0 seconds and “QUICK START” is set to 2, the acceleration delay with a rapid increase in the throttle will be 1.5 seconds. (3 divided by 2.) This function has no effect on the braking capacity.

The “TAPER RATE” function sets how quickly the reversing of the field current should be when changing direction.

If the value is too low, this produces an abrupt reversing.

“RESTRAINT” sets how powerfully the truck brakes with reduced throttle when the response of the speed controller is reduced.

With the speed controller in neutral and the brake switch actuated, the regulator strives to hold the truck still. This implies that if the truck is standing on a slope with the brake released it will only roll down the slope at very low speed. This speed is necessary for the regulator to be able to detect that truck is not standing on level ground.

Even when driving down a slope the speed will be regulated to the speed corresponding to the actual speed controller position in the required direction. It is therefore not necessary to move the speed controller in the opposite direction.

Transistor system Curtis 1243

ATLET SERVICE MANUAL

10.12

Electrical system

The “BRAKE CURRENT LIMIT” function maximises the armature current to the motor, which corresponds to the braking force during reverse braking.

“BRAKE RATE” sets according to which rate the braking current increases during the start of the reverse braking, i.e. how quickly the braking force is built up.

The time can be set between 0.1 and 3.0 seconds.

A longer time produces smoother braking.

The “CURRENT RATIO” function defines how much of the set current limit is available during different responses of the speed controller.

The current ratio can be set to the following values: 1=1:1 2=2:1 3=4:1 4=8:1 Example: If the value is set to 1 the current limit follows the actual movement of the speed controller.

If the value is set to 3 the current limit, e.g. with 20% speed controller deviation, will be 3 x 20 % of the set current limit value. This implies that the regulator will now produce max 60% (3 x 20 %) of the set current limit value. There will be certain variations if “THROTTLE MAP” is not set to 50%.

The “DECEL RATE” function adjusts the rate to which the braking force is set when reducing the speed controller’s response.

10.6.2

Hand terminal

The Hand terminal is used for adjustments and trouble shooting. The terminal is connected to the Curtis system via a connector to the left of the connector for connection of the control cabling. The same Hand terminal is used for Curtis 1207 and Curtis 1243, but a different cable is required.

Important!

When the Hand terminal is connected to the system the brake switch must be switched off until the terminal’s display shows the system’s Model number, Manufacturing date and Program version.

ATLET SERVICE MANUAL

Transistor system Curtis 1243

Electrical system

10.13

ICS

OST

GN

DIA T

TES AM

GR

PRO

GE AN E CHVALU LL ROLAY SCIS P D

RE

MO

O

INF

SM O48.1

Figure 10.6 Hand terminal The Hand terminal is operated with the eight buttons on the front. The top three buttons select the type of work to be done.

Table 10.3 Button

Description

“PROGRAM”

Used to set system parameters.

“TEST”

Used to test input signals, output signals and temperature inside the system.

“DIAGNOSTICS”

Used to read the faults registered by the system.

The following buttons are used to browse through the menus and to change settings.

Table 10.4 Button

Description

“SCROLL DISPLAY”

Browses in the menu. The current row is at the top of the display.

“CHANGE VALUE”

Changes the value or function of the set parameter.

“MORE INFO”

Here you can obtain more detailed information on the set function.

Transistor system Curtis 1243

ATLET SERVICE MANUAL

10.14

Electrical system

10.6.3

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: Table 10.5 Display text

Explanation

RESET ALL SETTINGS

Return to previous settings. (Setting when the Hand terminal was connected). Can only be done if the system has not been dead, or the Hand terminal has not been disconnected after the 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.

PROGRAMMER INFO

Shows Hand terminal information. Program versions etc.

CONTROLLER INFO

Shows system information. Program versions etc.

10.6.4

Special Diagnostics

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 with regard to faults, stored since this memory was last cleared.

To access the log with diagnostics history the brake switch in the truck must be open, i.e. the brake applied.

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 (see above), select “CLEAR DIAGNOSTIC HISTORY” and press the “MORE INFO” button for more information.

10.6.5

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 “RESET ALL 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.

ATLET SERVICE MANUAL

Transistor system Curtis 1243

Electrical system

10.6.6

10.15

Adjustment instructions

Curtis 1243 can be adjusted in two ways. Either with the Hand terminal step-bystep, or by copying between two systems.

With Hand terminal: 1 Go into the Hand terminal’s “PROGRAM” function.

2. Browse through the menu with the “SCROLL DISPLAY” buttons.

3. Set the required value of functions with the “CHANGE VALUE” buttons.

4. It is always the top row in the display that can be set.

5. The parameters M1 to M4 refer to setting the actual functions in groups, where the required group is selected by using the two inputs “MODE SELECT 1” and “MODE SELECT 2” in combination.

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 To carry out the transfer, press : CHANGE VALUE

To cancel, press:

CHANGE VALUE

The Hand terminal responds: "......WORKING"

Transistor system Curtis 1243

ATLET SERVICE MANUAL

10.16

Electrical system

And then: ALL CONT SETTINGS SAVED FROM PROGRAMMER This means that all the values from the regulator are copied to the Hand terminal.

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 To carry out the copying, press: CHANGE VALUE

To cancel, press:

7.

CHANGE VALUE

If you have selected to copy, the display shows: ".......Working" And then: ALL PROG. SETTINGS SAVED

IN CONTR 8. Copying is completed.

9. To copy to additional systems, connect to the required regulator and repeat points 1-7.

10. To return to the main menu, press “PROGRAM”.

11. The program remains in the Hand terminal for future copying.

Separate adjustments: It is possible to adjust the following functions in four different groups M1-M4 in the regulator.

ATLET SERVICE MANUAL

Transistor system Curtis 1243

Electrical system

10.17

- CURRENT LIMIT DURING DRIVING

(Drive current limit)

- CURRENT LIMIT DURING BRAKING

(Brake current limit)

- BRAKE RAMP

(Brake rate)

- BRAKING FORCE DURING REDUCED THROTTLE

(Decel rate)

- SPEED REDUCING

(Max speed)

- CONDITIONS DURING CHANGE OF DIRECTION

(Restraint)

A combination of two inputs (Mode Select 1 and 2) is used to access these groups.

OP models utilise the standard version for speed reducing at different lift heights, or other conditions that require reduced speed. Modes 1-3 are used for speed reducing and other functions when the lift height is over the stability level for max speed, or for other circumstances that require a reduction in speed.

Mode 4 is used for unlimited speed. To access these the inputs Mode select 1 and 2 must have battery voltage. Mode 1 is on pin 14. Mode 2 is on pin 9.

Table 10.6 Adjusting values Function

Description

VOLTAGE

Value

Nominal battery voltage 2 = 24V

2

Current limit in drive position Ampere

300

Current limit in braking position

50

BRAKE C/L (M1-M4)

Current limit in braking position

150

ACCEL RATE M1

Delay rate for acceleration in Mode 1 Seconds

1,7

ACCEL RATE M2

Delay rate for acceleration in Mode 2 Seconds

1,7

ACCEL RATE M3

Delay rate for acceleration in Mode 3 Seconds

1,7

ACCEL RATE M4

Delay rate for acceleration in Mode 4 Seconds

0,5

DECEL RATE (M1-M4)

Rate for delay of braking force. See separate description.

0,9

THROTTLE DECEL

Braking force during reduced throttle. Higher value gives lower braking force

0,3

BRAKE RATE (M1-M4)

Rate for delay of braking force. See separate description.

0,5

QUICK START

See description.

0

TAPER RATE

See description.

15

DRIVE C/L

(M1-M4)

BRAKE C/L

M1

MAX SPEED

M1

Max speed in Mode 1

32

MAX SPEED

M2

Max speed in Mode 2

32

MAX SPEED

M3

Max speed in Mode 3

32

MAX SPEED

M4

Max speed in Mode 4

100

Creep speed. The lowest speed that can be obtained when the speed controller is activated.

5

CREEP SPEED

Transistor system Curtis 1243

ATLET SERVICE MANUAL

10.18

Electrical system

Table 10.6 Adjusting values Function

Description

Value

THROTTLE TYPE

Type of speed controller.

THRTL DEADBAND

Deadband round the neutral position of the speed controller

10,0

THROTTLE MAX

The throttle voltage required to produce full speed.

Given in percent of full modulation

90

THROTTLE MAP

Speed at 50 % throttle in percent of full speed

40

FIELD MIN

Minimum field current. See separate description

6,8

FIELD MAX

See separate description

25,0

FIELD MAP START

See separate description

115

FIELD MAP

Field current in percent of max field current at 50 % of max armature current

50

CURRENT RATIO

See separate description

4

RESTRAINT

Braking force with reduction of speed controller response

10

LOAD COMP

Load compensated speed

0,0

HPD

Prevents start if the throttle voltage is higher than 25 % of max

0

SRO

Prevents start if in wrong sequence

0

SEQUENCING DELAY

Sequencing delay with SRO and HPD

1,0

MAIN CONT INTR

Determines if the main contactor should be controlled by the control switch, or always be connected.

Off

MAIN OPEN DELAY

Delay in switching off the above function

0

CONT DIAG

Diagnostics of the main contactor

Off

AUX TYPE

Selected type of auxiliary function when the truck has stopped after automatic reversing.

0

AUX DELAY

Delay of the above function.

0,0

EMR REV C/L

Current limit during actuation of emergency switch Ampere

50

EMR REV CHECK

Cable check of emergency switch function.

Off

EMR DIR INTR

If “On” the directional switch must be reset after emergency stop, and if “Off” also the brake switch.

Off

VARIABLE BRAKE

Adjusts the braking force during reverse braking.

On

ANTI-TIEDOWN

Monitoring of safety switch

Off

POT LOW FAULT

Monitors cable connection to the speed controller’s negative side.

On

FAULT CODE

Presentation of fault codes on outputs in the control switch

Off

ATLET SERVICE MANUAL

Should be type 2.

2

Transistor system Curtis 1243

Electrical system

10.19

Table 10.7 Truck OP

10.6.7

Speed of empty truck 9.0 km/h

Function and Installation checking

Before the truck is used after assembling or major work on the electrical system, the following must be checked.

Warning!

During function checks the truck must for safety reasons be jacked-up, with the drive wheel over the floor.

Warning!

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 Connect the Hand terminal. There are two different cables for the Hand terminal, one for the 1207 model and one for the 1243 model.

2. Switch on the key switch.

The Hand terminal’s display should now light up.

The LED in the middle of the regulator’s plastic cover should start flashing steadily with single flashes.

If the LED does not go on, check that there is voltage between pin 16 on the control switch and B- where the battery minus is connected to the regulator.

If there is battery voltage but the LED still does not light up, replace the system.

If the LED flashes in a combination, interpret the combination, or if the Hand terminal is available select “DIAGNOSTIC” and read-off the fault message.

If the Hand terminal shows “NO KNOWN FAULTS” the regulator cannot detect a fault.

Release the brake (close the brake switch); the LED should still flash with one flash in steady frequency.

The Hand terminal display should still show “No Known Faults”.

Transistor system Curtis 1243

ATLET SERVICE MANUAL

10.20

Electrical system

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.

When checking without the Hand terminal refer to section 10.6.7 to translate the flashes to a fault message. There are also translations of the Hand terminal’s English texts.

Note!

When the fault is rectified it may be necessary to switch the key switch off and on to clear the fault message.

3.

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, the motor, and the cabling.

The motor should rotate with a speed proportional to the throttle. If not, read the trouble shooting instructions.

4.

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. If the display shows “ON” the system considers the switch to be closed. “OFF” implies that the regulator considers the switch to be open. Check also that the speed controller varies from 0100%.

5.

Set the truck down on the floor, and drive in a free area. It should have smooth acceleration, good top speed, and good response.

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 “VARIABLE BRAKE” in “PROGRAM” mode is set to “ON”.

6.

ATLET SERVICE MANUAL

Transistor system Curtis 1243

Electrical system

10.6.8

10.21

Trouble shooting by means of LED

During normal operation the LED should flash with a steady frequency. If a fault is detected the LED starts to flash a two-digit code until the fault is rectified.

Example: ¤¤ ¤¤¤

¤¤ ¤¤¤

¤¤ ¤¤¤

(2 3)

(2 3)

(2 3)

Check the code 2,3 in the table below.

Table 10.8 Trouble shooting by means of Hand terminal CODE

Hand terminal shows

Possible reasons

Explanation

LED off

No voltage to the system, or system defective.

Steady

_____

1

¤

No known fault

1,1

¤¤

Current Shunt Fault

Regulator defective.

Defective current sensor.

1,2

¤ ¤¤

HW Failsafe

Regulator defective.

Hardware fault in regulator.

1,3

¤ ¤¤¤

M-shorted

Regulator defective.

M-fault or motor short-circuited.

1,4

¤ ¤¤¤¤

SRO

Incorrect type of SRO selected.

See adjustments table.

Sequence fault in start up.

2,1

¤¤ ¤

Throttle Fault 1

1. Break in cable from throttle.

2. Cable from throttle shorted to B+ or B-.

3. Throttle unit defective.

4. Incorrect throttle type selected (should be = 2).

Incorrect input signal from throttle.

2,2

¤¤ ¤¤

Emr Rev Wiring

Break in cable from emergency switch.

Emergency switch fault.

2,3

¤¤ ¤¤¤

HPD

1. Incorrect HPD type selected (for OP = 0).

2. Defective sequence between key switch/throttle.

3. Incorrectly adjusted throttle unit.

4. Too short sequence delay.

HPD fault.

Transistor system Curtis 1243

Defective regulator.

No faults detected.

ATLET SERVICE MANUAL

10.22

Electrical system

Table 10.8 Trouble shooting by means of Hand terminal CODE

Hand terminal shows

Possible reasons

Explanation

2,4

¤¤ ¤¤¤¤

Throttle Fault 2

1. Break in cable from throttle unit.

2. Short-circuit in cable to throttle unit.

3. Incorrect throttle type selected (should be = 2).

Break or shortcircuit in minus connection to throttle unit.

3,1

¤¤¤ ¤

Cont coil / field shorted

1. Main contactor coil shortcircuited.

2. Field winding short-circuited.

Overcurrent in contactor output or field output.

3,2

¤¤¤ ¤¤

Main Contactor Welded

1. Main contactor contacts welded 2. Main contactor output shortcircuited.

Welded main contactor.

3,3

¤¤¤ ¤¤¤

Field Open

1. Break in cabling to field winding.

2. Break in field winding.

Break in field winding.

3,4

¤¤¤ ¤¤¤¤

Missing Contactor

1. Break in contactor coil.

2. Main contactor defective.

3. Break in cable to main contactor.

Main contactor does not close.

4,1

¤¤¤¤ ¤

Low Battery Voltage

1. Battery voltage less than 16.8 V. 2. Corroded battery terminals.

3. Loose battery connections.

Low battery voltage.

4,2

¤¤¤¤ ¤¤

Overvoltage

1. Battery voltage over max permitted level.

2. Battery charger connected during operation.

Overvoltage.

4,3

¤¤¤¤ ¤¤¤

Thermal Cutback

1. Temp. over 85*C or below 25*C. 2. Excessive load.

3. Too high ambient temperature..

Reduced output as a result of too high temp. in regulator.

4,4

¤¤¤¤ ¤¤¤¤

Anti-tiedown

1. Mode switch constant to B+.

Anti-Tiedown fault.

ATLET SERVICE MANUAL

Transistor system Curtis 1243

Electrical system

10.6.9

10.23

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 switch.

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.

Press the “TEST” button. The display now shows the upper inputs. Test them by actuating the respective input and checking if the display shows the expected value.

If not, investigate the reason.

Table 10.9 Test menu The display shows

Function

THROTTLE %

Voltage from speed controller

% of full throttle

FIELD CURRENT

Field current to drive motor

Ampere

ARM CURRENT

Armature current to drive motor

Ampere

FIELD PWM

Field current’s pulse width ratio on/off

%

ARM PWM

Armature current’s pulse width ratio on/off

%

BATT VOLTAGE

Battery voltage in to regulator

Volt

HEATSINK C

Temperature of regulator’s cooling flange internally

Degrees C

FORWARD INPUT

Directional switch for Forward

On / Off

REVERSE INPUT

Directional switch for Reverse

On / Off

MODE INPUT A

Mode select switch 1

On / Off

MODE INPUT B

Mode select switch 2

On / Off

INTERLOCK

Brake switch

On / Off

EMP REV INPUT

Emergency reversing switch

On / Off

MAIN CONTACTOR

Main contactor

On / Off

AUX DRIVER

Unused auxiliary output

Transistor system Curtis 1243

ATLET SERVICE MANUAL

10.24

Electrical system

10.6.10 Specifications

Battery voltages:

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:

> 7.5 Volt for high input signal < 1.0 Volt for low input signal

Ambient temperature:

-40 - + 50 degrees Celsius.

Temperature monitoring (internally):

+85 degrees - + 95 degrees 100% - 0% current limit

Lower temperature limit (internally in the -25 degrees (50% of current limit) system):

ATLET SERVICE MANUAL

Transistor system Curtis 1243

Electrical system

10.7

10.25

Regulator, electric valve 0

Adjusting of regulator electric valve, see section 8

Regulator, electric valve

ATLET SERVICE MANUAL

10.26

10.8

Electrical system

Wiring diagram 0

Table 10.10 To OP-1429 Description

Machine type

Reference

Document code

Wiring diagram

OP

103300

Wiring diagram

OP

103301

Wiring diagram extra accessories

OP

103302

Table 10.11 From OP-1429 Description

Machine type

Reference

Document code

Wiring diagram

OP

103600

Wiring diagram

OP

103599

Wiring diagram extra accessories

OP

103602

Table 10.12 From OP DTFV -1429 Description

Machine type

Reference

Document code

Wiring diagram

OP

105902

Wiring diagram

OP

105901

Wiring diagram extra accessories

OP

103302

ATLET SERVICE MANUAL

Wiring diagram

SERVICE MANUAL Machine: OP Manual nr: 005949

Edition 2001A

Speed control and brake systems

11.1 Control lever .............................................................................................................. 11.1 11.1.1 Replacing the speed controller .................................................................... 11.1 11.1.2 Replacing the lifting/lowering switch ............................................................ 11.2 11.1.3 Replacing the green button ......................................................................... 11.2 11.1 Electric brake ............................................................................................................. 11.3 11.1.1 Electric brake 1 stage, 1 disc ....................................................................... 11.3 11.2 Adjusting the electric brake ..................................................................................... 11.5

ATLET SERVICE MANUAL

ATLET SERVICE MANUAL

Speed control and brake systems

11.1

Edition 2001A

11 Speed control and brake systems 00000000

11.1

Control lever 0

The speed controller controls the drive direction of the truck and its speed. The speed controller is of the electronic type and provides a signal on the direction of travel through signals to the drive regulator The speed controller contains an electronic control circuit with a proportional output sensor, which regulates the driving speed of the truck, i.e. the modulation from the transistor drive system.

Note!

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

11.1.1 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Control lever

Replacing the speed controller

Park the truck in a safe place where it cannot do any damage to the surroundings or yourself.

Switch off the main power.

Release the four socket head cap screws holding the cover.

Turn up the cover and release the contact block to the green button by unhooking the bayonet socket with a screwdriver.

Unscrew the hand rest by unscrewing the two retaining screws.

Unscrew the thumb control.

The button for the horn must be removed to access the retaining screws for the speed controller.

Release the button’s contact block holder by releasing the snap lock.

Release and remove the button by unscrewing the circlip with a check nut extractor.

Release the speed controller’s retaining screws.

Pull out the contact for the speed controller.

Assemble in the reverse order.

After fitting, check the speed controller so that everything runs smoothly when the thumb control is turned.

ATLET SERVICE MANUAL

11.2

Speed control and brake systems

SMOP_110100

Figure 11.1 Control lever, inside

11.1.2 1 2.

3.

4.

5.

6.

Park the truck in a safe place where it cannot do any damage to the surroundings or yourself.

Switch off the main power.

Release the four socket head cap screws holding the cover.

Turn up the cover and release the cables from the switch.

Release the switch from the cover by means of a screwdriver or a pair of pliers.

Assemble in the reverse order.

11.1.3 1 2.

3.

4.

5.

6.

7.

Replacing the lifting/lowering switch

Replacing the green button

Park the truck in a safe place where it cannot do any damage to the surroundings or yourself.

Switch off the main power.

Release the four socket head cap screws holding the cover.

Turn up the cover and release the contact block to the green button by unhooking the bayonet socket with a screwdriver.

Squeeze the bayonet tabs on the contact block holder together to release it from the button.

Release the button with a check nut extractor.

Assemble in the reverse order.

ATLET SERVICE MANUAL

Control lever

Speed control and brake systems

11.3

00000000

11.1

Electric brake The truck is braked with an electric brake. The electric brake is a safety brake with two friction surfaces. The braking torque, which can be adjusted with two adjusting screws, is created by spring pressure. The brake releases electromagnetically when actuated by a switch placed in the speed control housing. The brake released in one stage.

11.1.1

Electric brake 1 stage, 1 disc

When the brake is activated the springs, pos. 3Figure 11.1, press on the plate, pos.

2, which is pressed axially to the rotor, pos. 9. When the brake is released the coil,

Electric brake

ATLET SERVICE MANUAL

11.4

Speed control and brake systems

pos. 2, is supplied with battery voltage. The magnetic field created between the plate and the magnetic part allows the rotor to rotate freely.

1 2

4 6

3

7 5

3

8 2

9

10

11

H 180.1

Figure 11.1 Electric brake

ATLET SERVICE MANUAL

Electric brake

Speed control and brake systems

11.2

11.5

Adjusting the electric brake Adjusting is carried out in the following order.

1 Adjusting the A dimension: Fit the electric brake and tighten the bolts. Check the gap (A), see figure 11.2, between the magnetic part and the plate. If the gap needs adjusting, release the bolts holding the brake and turn the adjusting sleeves. Tighten the brake and check that the gap is the same all round.

A dimension 0.2 – 0.4 mm 2. 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.

Table 11.1 Braking distance Braking distance unloaded at 9 km/h

3.5m

Braking distance with rated load (see machine plate) at 8 km/h

3.1m

Adjust the T dimension until the correct braking distance is obtained.

T

A

SM104.1

Figure 11.2

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.

Adjusting the electric brake

ATLET SERVICE MANUAL

11.6

ATLET SERVICE MANUAL

Speed control and brake systems

Adjusting the electric brake