Atlet P Series PLP 200 & PLP 250 Service Manual - PDF DOWNLOAD

SERVICE MANUAL Machine: Manual No

PLP 119002

Edition 2008B

1 General information and technical data Scope of Service Manual ............................................................................................... 1.3 General ................................................................................................................ 1.3 Scope of the P series .......................................................................................... 1.3 How to use the manual .................................................................................................. 1.4 Structure .............................................................................................................. 1.4 Symbol key .......................................................................................................... 1.4 Safety instructions ......................................................................................................... 1.5 General ................................................................................................................ 1.5 Gas springs in platform and steering arm ............................................................ 1.6 Inspection/Preparation ................................................................................................... 1.6

Lifting the truck .................................................................................................... 1.6 Inspection/Preparation ................................................................................................... 1.6 Permitted lifting points .................................................................................................... 1.7

Welding on the truck ............................................................................................ 1.8 Atlet AB takes care of the environment ............................................................... 1.8 Environmental impact .......................................................................................... 1.8 Waste .................................................................................................................. 1.8 Preparations ................................................................................................................... 1.9 Service ................................................................................................................. 1.9 Trouble shooting .................................................................................................. 1.9 Data PLP ........................................................................................................................ 1.10 Designations ...................................................................................................... 1.10 Truck designation ......................................................................................................... 1.10 Type designation .......................................................................................................... 1.11

Dimensions and weights .................................................................................... 1.14 Machine specification ................................................................................................... 1.15

Component specification ................................................................................... 1.16 Recommended consumable materials ....................................................................... 1.17 SERVICE MANUAL

1.2

Oil and grease ....................................................................................................1.17 Standards and abbreviations .......................................................................................1.18 Screws ...............................................................................................................1.18 Tightening torque, screws and nuts .............................................................................. 1.18 Screw types and tensile grades .................................................................................... 1.18

Tightening torque, hydraulic couplings ...............................................................1.20 Conversion tables ..............................................................................................1.20 Standard abbreviations ......................................................................................1.21 Colour of the truck ..............................................................................................1.21 Colour codes, cabling ........................................................................................1.22 Designations ......................................................................................................1.22

SERVICE MANUAL

General information and technical data / Scope of Service Manual / General

1.3

Edition 2008B

1 General information and technical data Scope of Service Manual General This manual describes the service procedures for ATLET low lifter PLP. 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 upgrades, 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.

Unauthorised modification of the truck is not permitted. The user may only implement changes or modifications to the truck if the truck manufacturer no longer exists as a company and no other company has taken over the operations of the truck manuafacturer, on the assumption that the user: •

Arranges so that the modifications or changes are designed, tested and implemented by one or more experts on industrial trucks and their safety.

•

Prepares and archives documentation for the design, testing and implementation of the modifications or changes.

•

Approves and makes suitable changes to type plates, decals, and markings, and in the instruction manuals.

•

Attaches a permanent and clearly visible sign, or the equivalent, that reports in which way the truck has been modified or changed, together with the date of the modification or change and the name and address of the organisation that has conducted the assignment.

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.

Scope of the P series The manual covers the low lifters PLP 200 and PLP 250.

SM_PLP_01_119002_2008B.fm

SERVICE MANUAL

1.4

General information and technical data / How to use the manual / Structure

How to use the manual Structure The manual is built up according to the same principles as ATLET spare parts catalogues, with the truck divided into one subsystem per section.

Sections 1 - 3 in this manual contain more comprehensive information regarding technical data, general service instructions and tools.

Sections 4-12 in this manual contain information limited to a specific area in the truck concerning the description of the mechanical handling of different components, e.g.

Masts (section 6) and Hydraulic system (section 8).

The software is described in section 10.

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 in the manual.

Symbol key Warning!

Used for risk of personal injury.

Important!

Used for risk of damage to machine.

Note!

Used for general observation.

SERVICE MANUAL

General information and technical data / Safety instructions / General

1.5

Safety instructions General 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.

•

Local fire directives should always be followed.

•

The drive wheel should always be lifted up free from the floor during service work to prevent the vehicle from moving.

•

The battery plug should be pulled out before working on the electrical system. The battery plug may only be connected while trouble shooting, and when the greatest of care is exercised, (with the truck raised).

•

To prevent injuries caused by crushing the battery plug should always be removed when working on and around the mast and hydraulic unit. The mast or hydraulic unit can be actuated due to an electrical fault or a mistake while working.

Warning!

Having the power connected to the truck while working on and around the mast can lead to fatal injury!

•

When working on and around lifting devices and the hydraulic unit, they must be locked by using the mast lock, wooden blocks or some other appropriate means.

•

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

•

The system should not be pressurised, e.g. the pump motor switched off and the forks in their lowest position, when dismantling parts of the hydraulic system.

•

All metal objects such as watches, chains, spectacles 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.

SERVICE MANUAL

1.6

General information and technical data / Safety instructions / Gas springs in platform and steering

Gas springs in platform and steering arm Inspection/Preparation The functioning of the platform and steering arm should be checked. The gas springs in both of these functions are a very critical factor for their correct functioning.

Since the gas springs are exposed to dirt and a large number of operations, they should be checked very carefully during preventive maintenance.

During service and preventive maintenance it is important if the truck is a model with a foldable platform to check that the platform is raised up automatically when the driver gets off it. If this does not happen it should be reported to the truck supervisor, with the recommendation that the truck be taken out of service until the requisite measures have been implemented.

During service and preventive maintenance it is important to check that the steering arm is raised up automatically when the driver releases it. If this does not happen it should be reported to the truck supervisor, with the recommendation that the truck be taken out of service until the requisite measures have been implemented.

Warning!

Great caution must be observed when dismantling the gas springs.

• Make sure that no other persons are in the vicinity or in the lengthwise direction of the gas springs.

•

Stand to the side of the gas spring when removing.

•

Never point the gas spring toward any person or part of the body.

Lifting the truck Inspection/Preparation •

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.

•

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

SERVICE MANUAL

General information and technical data / Safety instructions / Lifting the truck

Permitted lifting points

Figure 1.1 Permitted lifting points

Figure1.1 shows where the permitted lifting points are placed on the truck.

Warning!

The machine must never be lifted in any other points than the ones shown.

Figure 1.2 shows where the jack should be placed.

Figure 1.2 Lifting point, jack

SERVICE MANUAL

1.7

1.8

General information and technical data / Safety instructions / Welding on the truck

Welding on the truck •

During welding work the battery plug should always be disconnected and all connections to the control units and controllers (applies to all electronic units) disconnected. On completion of welding work the contactors should first be connected to the electronic units, after which the battery plug is then connected to the battery.

•

The return cable clamp should always be connected as close to the welding area as possible to eliminate damage to surrounding components.

Atlet AB takes care of the environment The majority of our products consist of metal that can be completely recycled.

Environmental impact All products have an impact on the environment throughout their entire life cycle.

The consumption of energy during their use is one of the most important factors that influences the environment.

Through correct care, maintenance and use the consumption of energy can be reduced, thereby reducing the environmental impact.

Waste 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 should only be carried out in areas intended for this purpose.

Recyclable material should be taken care of by specialised authorities.

Environmentally hazardous waste, such as oil filters, batteries and electronics, can have a negative effect on the environment, or health, if handled incorrectly.

SERVICE MANUAL

General information and technical data / Preparations / Service

1.9

Preparations Service •

Go through all the safety instructions.

•

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

•

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

•

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

•

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.

Trouble shooting When you suspect that a component is defective, do not replace it immediately. First check the surrounding equipment and carry out complete trouble shooting according to the trouble shooting chart. Make sure you know the reason for the fault before replacing a component.

SERVICE MANUAL

1.10

General information and technical data / Data PLP / Designations

Data PLP Designations Truck designation Table 1.1 Truck designations

Truck type

Load capacity

PLP 200

Low lifter

PLP 250

Low lifter

PLP 200

2,000 kg

PLP 250

2,500 kg

SERVICE MANUAL

General information and technical data / Data PLP / Designations

1.11

Type designation

1 2 3 4

Modell Model Modell Modèle Serie nr.

Serial no.

Serien-Nr Nº de serie Tillverkningsår Year of construction Baujahr Année de construction Tillåten last Load capacity Tragfähigkeit Charge limite

Vikt utan batterie Weight without battery Gewicht ohne Batterie Poids propre sans batteri Batteri vikt min.

Battery weight min.

Batteriegewicht min.

Poids de batterie mini.

Batteri vikt max.

Battery weight max.

Batteriegewicht max.

Poids de batterie maxi.

Tyngdpunktsavstånd Distance of load center Lastschwerpunktabstand Distance de centre Tillverkare Manufacturer Hersteller Fabriccat

Batterispänning Batteryvoltage Batteriespannung Tension de la batterie

Kg

Kg

Kg

Kg

V- DC

Atlet AB Mölnlycke Sweden

Figure 1.3 Example of type plate (–2006w36)

1.

Model designation.

2.

Type Series no./Version (S=Special ver.).

3.

Year of manufacture, week, and warranty period in months (only Sweden).

(On the assumption that the service instructions in the warranty regulations are followed).

4.

Where appropriate, load limitations depending on the position of the load on the forks (D) and/or lifting height (Q).

SERVICE MANUAL

1.12

General information and technical data / Data PLP / Designations

1 2 3 4

Model Modell Serial no.

Serie nr.

Year of manufacturing Tillverkningsår Load capacity Tillåten last Load centre distance Tyngdpunktsavstånd Weight without battery Vikt utan batteri Battery weight min.

Batterivikt min.

Battery weight max.

Batterivikt max.

Battery voltage Batterispänning Refernce number Referensnummer

ATLET AB MÖLNLYCKE SWEDEN

Figure 1.4 Example of type plate (2006w37–)

1.

Model designation.

2.

Type Series no./Version (S=Special ver.).

3.

Year of manufacture, week, and warranty period in months (only Sweden).

(On the assumption that the service instructions in the warranty regulations are followed).

4.

Where appropriate, load limitations depending on the position of the load on the forks (D) and/or lifting height (Q).

SERVICE MANUAL

General information and technical data / Data PLP / Designations

1.13

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.

SER XXXXXX

WEEK XXXX

SER XXXXXX

WEEK XXXX

Figure 1.5 Example of plate with serial number.

Explanation of Model designation Example:

PLP 200

Truck type Load capacity/10 Battery Ah/5 Charger Ampere

SERVICE MANUAL

160 30

General information and technical data / Data PLP / Dimensions and weights

Dimensions and weights

L2

L4

453

H1

149

52

180

H4

55

877

634

1595

Dimensions PLP

919

L1 L3

R2

Figure 1.6 Positions for dimensions PLP

SERVICE MANUAL

V

B

560

B2

B1

L

578

1.14

General information and technical data / Data PLP / Dimensions and weights

Machine specification No.

PLP 200

PLP 250

1 1a

Lifting capacity, rated Distance to centre of gravity

Q D

kg mm

2000 600

2500 600

2 2a

Lifting height Mast height

200

Transport free lift Full free lift Straddle lift

mm mm mm mm

200

2b 2c 2d

H4 H3 H5 H2

4 4a

Lifting speed without load – with rated load Lifting time without load – with rated load

m/s s

2.0-2.5

2.0-2.7

5

Lowering speed without load – with rated load Lifting time without load – with rated load

m/s s

2.5

2.5

km/h m/s

10.0-8.5 2.77-2.36

12.0-9 3.3-2.77

Max

%

10-10

10-10

770 + L2

835 + L2

6

Driving speed without load – with rated load Driving speed without load – with rated load

8

Reversing capacity without load – with rated load

10

Turning radius

R2

mm

11

Minimum aisle width Ast incl. 200 mm R2-L2 + load length + 200 Load length 800 mm Load length 1,000 mm Load length 1,200 mm

Ast Ast Ast

mm mm mm

13

Height over protective roof

H6

mm

14

Truck length

L

mm

750 + L1

825 + L1

15

Truck width

B

mm

770

770

16

Fork length, std

L1

mm

1000 / 2375

1000 / 2375

17 17a

Width over forks, std max-min Width between fork gaffel shanks

W

mm mm

680 / 460 W - 350

680 / 480 W - 350

19

Truck length to fork support area

L4

mm

750

825

20 20a

Fork arm, width – thickness For height, min

B1 H1

mm mm

175 - 55 85

175 - 55 85

21

Straddle lift height

H7

mm

22

Width between fork straddle lift

B2

mm

23

Dim. for front axle – fork support area

L2

mm

785 - 1765

785 - 1465

24

Wheelbase

L3

mm

551 + L2

626 + L2

25

Wheel track – front, back centre of wheel

mm

W - 175/526

W - 175/526

26

Ground clearance, half wheelbase load

mm

30 - 145

30 - 145

27

Service weight with/without battery

kg

860 - 530

925 - 545

28

Max axle pressure, load wheel with/without rated load

kg

212 / 1828

212 / 2238

29

Max axle pressure, drive wheel with/without rated load

kg

705 - 1110

715 - 1215

39

Battery capacity

39a

Battery voltage

kWh Ah V

4.8-9.6 200-400 24

7.5-14.4 300-600 24

41

Traction motor

kW

2.2 / 2.4 AC

2.2 / 2.4 AC

42

Speed controlling

Transistor

Transistor

43 43a

Lift motor Hydraulic tank

2.2 - 12/10 9

2.2 - 12/10 11

44 44a

Wheel type Number of drive/castor/load wheels

Vulkollan 3-4

Vulkollan 3-4

kW - %/ min MPa

SERVICE MANUAL

1.15

1.16

General information and technical data / Data PLP / Component specification

45 45a 45b 45c

Wheel dimensions Load wheel D* width Drive wheel D* width Castor wheel

46

Control system

47 48

mm mm mm

(4x) 85x75 (1x) 230x90 (2x) 150x60

(4x) 85x75 (1x) 230x90 (2x) 150x60

Tiller arm

Tiller arm

Main brake, type – actuated part

El. drive mech.

El. drive mech.

Parking brake, type – actuated part

El. drive mech.

El. drive mech.

Component specification Table 1.2 Component specification Component

Specification

Traction motor

Drive voltage

24V

Output standard

2.2 / 2.4 kW 60 min

Gear ratio (standard)

15:1

Oil volume

0.85 litre

Max pressure

21 MPa

Oil volume

max 1.6 litre

Hydraulic unit (motor and pump)

Output

2.2 kW

Control system for traction motor

Type FZ2007

AC1 CAN

Voltage

24 V

Max current

250A (RMS) for 2 min

Control fuse 1

5A

Pump motor fuse 1

250 A

Traction motor fuse 1

250 A

Gearbox

Hydraulic system

Fuses

SERVICE MANUAL

General information and technical data / Recommended consumable materials / Oil and grease

Recommended consumable materials Oil and grease Table 1.3 Table of recommended types of oil and grease Brand

Gearbox oil As per API value GL-5 Normal

Cold store

Hydraulic oil As per ISO VG 32, VG 15 Normal (32)

Cold store (15) BP Bartran SHF-S

Bearing grease NLGI 2 Lithium base

BP

BP Energear BP Energear HYPO SHX-S 80W/140 EP 75W/140 EP

BP Bartran HV-32

Energrease LC 2

Castrol

-

-

Hyspin SHS 32

Hydraulic oil OM 15 Alt: Hyspin AWH 15

LMx

Mobil

-

-

DTE 13 M SHS 32

Flowrex 1

Mobilplex 48

Shell

-

-

Tellus oil TX 32

Tellus oil T 15

Retinax EP2

Statoil / Exxon

-

-

SHS 32

J 26

Uniway LIX 625

Texaco

-

-

Rando oil HDZ 32

Rando oil HDZ 15

Hytex EP2

Important!

Do not mix different lubricants, and absolutely not synthetic oil with mineral oil, since this can affect the properties of the oil!

SERVICE MANUAL

1.18

General information and technical data / Standards and abbreviations / Screws

Standards and abbreviations Screws Tightening torque, screws and nuts Table 1.4 Tightening torque, screws and nuts DIM

Tensile grade 4.6

8.8

10.9

12.9

Nm

Nm

Nm

Nm

M4

1.1

2.9

4.0

4.9

M5

2.2

5.7

8.1

9.7

M6

3.7

9.8

14

17

M8

8.9

24

33

40

M10

17

47

65

79

M12

30

81

114

136

M14

48

128

181

217

M16

74

197

277

333

M18

103

275

386

463

M20

144

385

541

649

The tightening torque in the table 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.

Screw types and tensile grades Table 1.5 Figure

Screw type

Designation

Tensile grade

M6S

Hexagon screw

8.8 10.9

MC6S

Hexagon hole screw

8.8 10.9 12.9

SERVICE MANUAL

General information and technical data / Standards and abbreviations / Screws

1.19

Table 1.5 Figure

Screw type

Designation

Tensile grade

MF6S

Hexagon hole screw, countersunk

10.9

MCS

Slotted screw

4.6

MVBF

Oval head countersunk screw

4.6

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

8.8 8.8

12.9 12.9

Figure 1.7 Example of marking

SERVICE MANUAL

1.20

General information and technical data / Standards and abbreviations / Tightening torque, hydrau-

Tightening torque, hydraulic couplings Table 1.6 Tightening torque, hydraulic couplings 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 pipe olive

MA (Nm) with elastic (O-ring coupling)

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

400

140

M18 x 1.5 M20 x 1.5

M27 x 1.5

G 1/2"

G 3/4"

M27 x 2 G 1" M33 x 2 M42 x 2

G 11/4"

600

240

M48 x 2

G 11/2"

800

300

Conversion tables Table 1.7 Conversion table, torque units 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

SERVICE MANUAL

General information and technical data / Standards and abbreviations / Standard abbreviations

Table 1.8 Conversion table, pressure units Pa (N/m2)

Bar (1mb=1hPa)

at (kp/cm2)

dry (mm Hg, 0 C)

atm

1

10 -5

1.020*10 -5

7.501*10 -3

9.869*10 -6

9.807*10 4

0.9807

1

735.6

0.9678

133.3

1.333*10 -3

1.360*10 -3

1

1.316*10 -3

1.013*10 5

1.013

1.033

760

1

Table 1.9 Conversion table, speed m/s

km/h

1

3.6

0.278

1

Standard abbreviations Table 1.10 Standard abbreviations Magnitude

Unit

Designation

Current

Ampere

A

Voltage

Volt

V

Resistance

Ohm

Ω

Output

Watt

W

Torque

Newton metre

Nm

Pressure

Pascal

Pa

Colour of the truck 0

The truck is painted in colours with the following NCS colour codes: Table 1.11 NCS colour codes Machine colour

Designation

Yellow

NCS 0070-Y20R

Medium grey

NCS 7000

Dark grey

NCS 8000

SERVICE MANUAL

1.22

General information and technical data / Standards and abbreviations / Colour codes, cabling

Colour codes, cabling The colour markings of all cables included in the truck can be seen in the Atlet wiring diagrams. The abbreviations have the following significance: Table 1.12 Colour codes Atlet wiring diagrams Code

Cable colour

Y

Yellow

BL

Blue

SB

Black

W

White

GN

Green

GR

Grey

R

Red

BN

Brown

VO

Violet

P

Pink

OR

Orange

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.

Designations Electrical components normally have a designation of two letters: Table 1.13 First letter Code

Designation

A

Component or function without its own letter below

C

Capacitor

D/V

Diode

E

Electrical component

F

Fuse

I

Indicator

K

Contactor/relay

L

Coil/inductive element

SERVICE MANUAL

General information and technical data / Standards and abbreviations / Designations

Table 1.13 First letter Code

Designation

M

Motor

P/X

Connection

R

Resistor

S

Switch/Change-over switch

T

Terminal

Y

Valve/brake

H

Audible warning unit/lamps/lights

G

Battery Table 1.14 Second letter Code

Designation

B

Brake

C

Control system

E

Emergency function

F

Forward

H

Hour

K

Key

L

Lower

M

Manoeuvre

P

Pump

R

Reverse

S

Speed

SERVICE MANUAL

1.23

1.24

General information and technical data / Standards and abbreviations / Designations

SERVICE MANUAL

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2007B

2 Special tools Special tools PLP ........................................................................................................... 2.3 Introduction .......................................................................................................... 2.3 List of tools .......................................................................................................... 2.3

SERVICE MANUAL

2.2

SERVICE MANUAL

Special tools / Special tools PLP / Introduction

2.3

Edition 2007B

2 Special tools Special tools PLP Introduction All special tools can be ordered from Atlet AB.

List of tools Table 2.1 List of tools Designation

Figure

Part number

Applications

Cleaning fluid

P/N 112268

Cleaning of electric motors from gearbox oil and other dirt

Chain spray

P/N 001196

Lubrication of chains

Crimping tool Molex

P/N 006454

Cable connections

Pin extractor

P/N 006456

Cable connector

Lifting eye

P/N 104737

Lifting eye for drive unit.

P/N 118515

Lifting tool

Lifting device

2.1

For detailed information on the above products, please contact Atlet.

SM_PLP_02_0001A.eps Bild 2.1 Lifting device

SM_PLP_02_119002_2007B.fm

SERVICE MANUAL

2.4

Special tools / Special tools PLP / List of tools

SERVICE MANUAL

SERVICE MANUAL Macine: Manual No:

PLP 119002

Edition 2007B

3 Service Regular maintenance 3 Introduction .......................................................................................................... 3.3 Safety .................................................................................................................. 3.3 Recommendation ................................................................................................ 3.3 Daily inspection ................................................................................................... 3.4 This is the responsibility of the truck driver (before each shift). ..................................... 3.4 This is the responsibility of the truck driver (after each shift). ........................................ 3.4

Weekly inspection (30 hours of operation) .......................................................... 3.5 Responsibility: Truck driver ............................................................................................ 3.5

First service ......................................................................................................... 3.5 Main service ........................................................................................................ 3.5 Extra service inspections ..................................................................................... 3.6 Check list, service inspection .............................................................................. 3.7 Code explanation ................................................................................................3.11 Lubrication chart ................................................................................................ 3.15 PLP ............................................................................................................................... 3.15 Symbol key, lubrication chart ....................................................................................... 3.16

Specific instructions 17 Traction motor ................................................................................................... 3.17 Preventive maintenance ............................................................................................... 3.17

Gearbox ............................................................................................................. 3.17 First service .................................................................................................................. 3.17 Preventive maintenance ............................................................................................... 3.17

Lift chains and forks ........................................................................................... 3.18 Check ........................................................................................................................... 3.18

Hydraulic oil ....................................................................................................... 3.19 First service .................................................................................................................. 3.19 Intervals ........................................................................................................................ 3.19

Emergency stop ................................................................................................. 3.19 Recommended replacement ............................................................................. 3.20 Storage of machines and motors ....................................................................... 3.20

SERVICE MANUAL

3.2

SERVICE MANUAL

Service / Regular maintenance / Introduction

3.3

Edition 2007B

3 Service Regular maintenance Introduction Preventive maintenance should be carried out regularly when the truck is used in normal conditions. The planned service includes operations such as test driving, function tests, and the changing of filters and oils etc. Service is planned at different intervals depending on the running time of the truck. If the truck is working in extreme conditions or in demanding environments, servicing must be planned at tighter intervals.

Safety Important!

Check under each separate section which safety instructions are applicable for work on the truck.

Inspection of the external functions in the power steering system should be carried out after every service and after work carried out in the electrical system. All function tests of the safety system should be made with the speed controller in neutral position, see section 10.

Recommendation Information on what the truck owner should take into consideration.

Regular inspection should be carried out by specially appointed and trained personnel with a good working knowledge of the function and maintenance of the truck.

To obtain the best results from your investment in your truck we advise you to contact your local Atlet representative and to sign up for a service contract for regular inspection.

SM_PLP_03_119002_2007B.fm

SERVICE MANUAL

3.4

Service / Regular maintenance / Daily inspection

Daily inspection (This section is an extract from the driver instructions.)

This section provides information on what the truck owner should take into consideration.

Important!

Naked flames or smoking are prohibited when checking the specific acid weight and level.

When changing or checking the battery use ergonomic work procedures to avoid injury.

This is the responsibility of the truck driver (before each shift).

1.

The battery should be checked every day. See separate maintenance instruction.

Note that the acid level rises somewhat during charging.

2.

Check that the battery cables, connections and plugs are connected correctly and not damaged.

3.

Check that the battery is properly secured in its compartment.

4.

Check if the truck has leaked oil.

5.

Check the transport and safety signals.

6.

Check the braking effect on the main brake and parking brake.

7.

Check for external damage on the wheels.

8.

On trucks equipped with a truck computer, check that there are no error messages on the display.

Important!

Faults detected during daily inspection are reported to the management. See driver instructions.

This is the responsibility of the truck driver (after each shift).

Battery charging Battery service should only be carried out by specially trained personnel. This training is given on truck driver courses. Batteries may, however, be charged by other personnel on the assumption that the battery plug is used to connect the battery to the charging unit.

The battery is charged in accordance with the recommendation from the battery manufacturer. Only fully automatic charging units should be used. If an unregulated charger is used the battery charging should be checked by measuring the specific acid weight in the cells.

SERVICE MANUAL

Service / Regular maintenance / Weekly inspection (30 hours of operation)

3.5

Important!

The specific acid weight should also be checked even when an automatic charger is used. For other information concerning batteries and fully automatic chargers, see the separate maintenance instructions on the battery and charger.

Weekly inspection (30 hours of operation) (This section is an extract from the driver instructions.)

Responsibility: Truck driver 1.

The battery is cleaned externally with hot water and rags.

2.

Check the oil level in the hydraulic system by pushing all the hydraulic cylinders to their end positions. Now check that the fork carriage goes all the way up to maximum lifting height without the pump sucking air.

3.

Check that the wheels have not separated – tread/hub and tread/cord.

4.

Check the specific acid weight. See separate battery maintenance instructions.

5.

The outside of the truck should be cleaned. Vacuum clean, and wipe with moist cloth in the driver cab. Use care when using a water hose. Electric panels and circuit boards should always be protected from splashed water when washing.

First service The first service should be carried out after 200 hours. This service has the purpose of ensuring the function of the truck and its component parts.

•

Change the oil in the gearbox.

•

Change the hydraulic oil filter.

•

Test the function of the entire machine in accordance with the following list.

Main service EN-1726 and ISO 3691 specify that regular preventive maintenance should be carried out on the truck. To guarantee high quality, operation reliability and personal safety, this maintenance should be carried out by Atlet Service or by personnel specially trained by Atlet. To comply with this requirement Atlet has prepared the following main service points (A service), which should be checked every 500 hours of operation.

•

Check for external damage on chassis.

•

Check of weld joints at vital points.

•

Check of lifting devices.

•

Check of component attachments.

•

Function test, control lever.

SERVICE MANUAL

3.6

Service / Regular maintenance / Extra service inspections

•

Check of the horn.

•

Test drive backwards and forwards, and turning.

•

Check of the drive unit.

•

Check of all the wheels.

•

Test of the brake function.

•

Oil and filter change according to instructions.

•

Check for oil leakage.

•

Check of the hydraulic unit, pipes and hoses.

•

Check of the cylinders.

•

Function test, lifting and lowering.

•

Lubrication in accordance with lubrication chart.

•

Measurement and check of the battery and charging function.

Extra service inspections What has been mentioned above is applicable on the assumption that the machine is working in normal conditions on single shifts. In dirty or dusty environments, poor floor conditions, or where there are large variations in temperatures, the service intervals must be arranged more frequently.

None of the above mentioned inspection can be debited to Atlet Products.

SERVICE MANUAL

Service / Regular maintenance / Check list, service inspection

3.7

Check list, service inspection For further information about procedures for inspections, repairs and replacements refer to respective sections. Planned service inspections are implemented in accordance with the following points: Chassis Inspection points

Symptom

Inspection

Service code

Signs/Decals

None, illegible

Visual

1024, 1101

Panels

Attachment, damage

Visual, tools

1102, 1032

Load wheel, Castor wheel

Damage, wear

Visual

1108, 1109

Noise

Listen, tool

Attachment

Visual, tools

Rubber mats, Rubber protectors

Damage

Visual

Attachment

Visual, tools

Chassis, general

Appearance

Visual

Damage

Visual

Loose screws

Tools

1105, 1058

1001, 1033, 1112

Mast Inspection points

Symptom

Inspection

Service code

Pull rods

Locking.

Tools

2105

Damage

Visual

Cracks, damage

Visual

Wear

Visual

Angle, deformation

Visual, tools

Cracks, damage

Visual

Play, damage, wear on rollers

Visual, operating test

Angle, deformation

Visual

Attachment rollers

Visual, tools

Cracks, damage

Visual

Wear, cracks

Visual

Forks

Fork carriage

Mast sections

2026

2007, 2004

2101

Drive unit Inspection points

Symptom

Inspection

Service code

Gearbox

Oil level

Visual, filling

Oil leakage

Visual, tools

3006, 3101, 3107

SERVICE MANUAL

3.8

Service / Regular maintenance / Check list, service inspection

Drive unit Inspection points

Symptom

Inspection

Service code

Traction motor

Function, noise

Listen, tool

Cable connections

Visual, tools

7028, 7113, 7039, 7027, 7112

Noise

Listen, tool

3002, 3005

Damage, wear

Visual

Attachment, play

Visual, tools

Sliding bearing

Noise

Listen, lubricate

3103

Drive shaft

Noise

Listen, tool

3104

Gear

Noise

Listen, tool

3102, 3106

Drive wheel

Steering Inspection points

Symptom

Inspection

Service code

Guide bearing

Noise

Listen, lubricate

4101

Tiller arm attachment

Play

Visual

4103

Attachment

Tools

Guide belt

Play

Visual

4005

Brake Inspection points

Symptom

Inspection

Service code

Braking force

Malfunction

Function test, tools

5012

Parking brake

Malfunction

Function test, tools

5014

Brake cable

Abrasion

Visual

5002

Brake disc

Wear

Visual, tools

5104

Hydraulic system Inspection points

Symptom

Inspection

Service code

Hydraulic tank

Oil level

Visual, filling

6012, 6102

Damage, leakage contamination

Visual, cleaning

Filter blocked

Visual, replace

SERVICE MANUAL

Service / Regular maintenance / Check list, service inspection

3.9

Hydraulic system Inspection points

Symptom

Inspection

Service code

Cylinders

Function

Function test, stopwatch

6001, 6017

Damage

Visual, replace

Leakage

Visual, tools, replace

Weld damage

Visual, tools, replace

Damage, chain attachments

Visual, tools

Leakage, damage

Visual, tools

Attachment

Visual, tools

Nipples

Leakage

Visual, tools

6019

Pump motor

Function, noise

Listen, tool

7030, 7029

Cable connections

Visual, tools

Leakage

Visual, tools

Damage

Visual, tools

Noise

Listen

Malfunction

Test

Leakage

Visual, tools

Malfunction

Test

Leakage

Visual, tools

Malfunction

Test

Leakage

Visual, tools

Hoses

Hydraulic pump

Relief valve

Solenoid valve

Prop. valve

6007, 6008

6109

6105

6018

6018

For more information regarding the hydraulic system, also see section 8 and lift cylinders section 9.

Electrical system Inspection points

Symptom

Inspection

Service code

Contactors

Malfunction

Visual, tools, replace

7107

Cable break

Visual, tools

Contactor tip

Visual, tools

SERVICE MANUAL

3.10

Service / Regular maintenance / Check list, service inspection

Electrical system Inspection points

Symptom

Inspection

Service code

Battery

Charging

Tools

7032

Low acid level

Tools

Low acid weight

Tools

Damage

Visual

Transistor system AC

Cable break

Visual, tools

7025

Cabling

Damage, break

Visual, tools

7007, 7009 7010, 7039 7104, 7112

Horn

Malfunction

Function test

7014

Speed controller

Attachment

Visual, tools

7011, 7106

Malfunction

Function test Calibration

Fuses

Blown

Visual, replace

7103

Battery plug

Malfunction

Function test, tools

7008

Hour meter

Malfunction

7012

Battery indicator

Malfunction

7013

Safety switch

Emergency stop

Malfunction

7020

Microswitch

Function

Function test

7017

ATC T4

Function Cable connections

Visual

7004

SERVICE MANUAL

Service / Regular maintenance / Code explanation

3.11

Code explanation Chassis Code

Designation

Check

Reference to section

1001

Machine housing

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

1

1024

Machine plate

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

1

1032

Panels

Attached with screws and clips, as well as bonded parts.

4

1033

Colour

Peeling of paint and attachment/lack of decals.

1

1042

Load guard

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

1

1058

Rubber strips

Attached with glue or screws/weld bolts

-

1101

Decals

Damage

-

1102

Chassis, covers

Damage, battery cover

4

1108 1109

Load wheel bearing Castor wheel bearing

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

Vulkollan wheel wear. Dirt.

4 6

1112

Accessories

User Manual, areometer and battery water bottle.

-

Mast Code

Designation

Check

Reference to section

2004

Frame section

Attachment of the mast in machine housing.

1

2007

Rollers in fork carriage

Washers. Lubrication of roller surfaces.

1 6

2026

Forks

Cracks, damage, parallelism, height over floor.

6

2101

Mast play

Check max play, Cams. Lubricate slide surfaces.

6

2102

Lift chains

Check wear.

4

2105

Push rods / Pull rods

Locking, damage

6

SERVICE MANUAL

3.12

Service / Regular maintenance / Code explanation

Drive unit Code

Designation

Check

Reference to section

3002

Drive wheel

Wear, damage, clean

5

3005

Drive wheel bolt

Attachment.

5

3006

Oil leakage

Leakage from axles, joints, plugs or material.

5

3101

Oil level

Oil level. Oil change.

1 5

3102

Noise

Gears.

5

3103

Sliding bearing

Noise, lubrication

5

3104

Drive shaft

Tightening, play

5

3106

Gears

Gear ratio

5

3107

Gear housing

Check wear.

5

Steering Code

Designation

Check

Reference to section

4103

Tiller arm attachment

Play, bushings, attachment

7

4104

Guide bearing

Play, lubrication

1 7

Brake unit Code

Designation

Check

Reference to section

5002

Brake cable

Attachment, damage

11

5012

Braking force

Braking distance

11

5014

Parking brake

Function, cable connections

11

5104

Brake discs

Friction surface> min level all round

11

SERVICE MANUAL

Service / Regular maintenance / Code explanation

3.13

Hydraulic system Code

Designation

Check

Reference to section

6001

Lift cylinders

Leakage at attachments, weld joints, scraper, piston rod

9

6007

Couplings

Leakage.

-

6008

Hoses

Cracks, wear, damage.

1

6012

Oil level in tank

Oil level between min and max.

1 8

6017

Lowering

Check lowering speed.

8

6018

Solenoid valve

Leakage in slide, connections, tightening.

-

6019

Nipples

Leakage. Tightening.

-

6102

Filter

Replace if necessary.

8

6105

Relief valve

Function, adjustment as per max lifting capacity. Locking.

8

6109

Hydraulic pump

Leakage between pump and motor.

-

SERVICE MANUAL

3.14

Service / Regular maintenance / Code explanation

Electrical system Code

Designation

Check

Reference to section

7004

Truck computer

Error log.

10

7007

Battery cables

Attachment, damage.

-

7008

Battery connections

That cable connections are not overheating.

Remove oxide.

-

7009

Main power cable

Attachment, damage.

-

7010

Control cable

Attachment, damage.

-

7011

Speed controller

Function.

-

7014

Horn

Function. Oxide deposits.

-

7017

Microswitch

Function. Attachment.

-

7020

Emergency switch

Function.

-

7025

Transistor system

Dirt, moisture. Cable connections, oxide.

-

7029

Pump motor carbon brushes

Wear.

8

7030

Pump motor

Attachment. Cleaning.

5

7032

Battery

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

-

7035

Speed switch

Switches in gates and platform that control creep speed. Attachment.

10

7103

Fuses

That they are not brittle, oxidised.

1

7104

Cabling

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

-

7106

Speed controller

Attachment and function.

11

7107

Contactors

Contact surfaces, cable connections, dust guard.

-

7112 7039

Traction motor cables

Attachment, damage, insulation, oxidation.

-

7113

Housing, traction motor

Noise, grease, play.

5

SERVICE MANUAL

Service / Regular maintenance / Lubrication chart

3.15

Lubrication chart PLP

A

B D C

E F

1 2

G

Figure 3.1 Lubrication chart PLP. For explanation of symbols, see table 3.2

1.

500 h service

2.

Annual service

All the panels must be removed when lubricating the truck, see section 4. The electric panel should also be released and folded back to improve access. The electric panel is fitted with two socket head cap screws to the battery wall. When lubricating the mast sections, push out the battery slightly and brush grease on the roller and slide surfaces.

Service on an Atlet truck can be divided into service that should be carried out regardless of how severely the truck is loaded and used (see "Check list, service inspection" on page 3.7) and an annual recurrent service:

SERVICE MANUAL

3.16

Service / Regular maintenance / Lubrication chart

Table 3.1 Components to lubricate, PLP Positioning

Explanation

A

Mast section – roller surfaces and slide surfaces

B

Gates – bearing surfaces lubricated

C

Spring-mounted drive unit – link bearings, 12 grease nipples

D

Hydraulic oil

E

Castor wheel - sliding bearings, 2 grease nipples

F

Gearbox oil

G

Platform, 2 grease nipples

Symbol key, lubrication chart Table 3.2 Symbol key for lubrication chart Symbol

Explanation

Symbol

Explanation

Hydraulic oil

Hydraulic oil, change

Gearbox oil

Gearbox oil, change

Grease

Chain spray

Chain spray / oil

Only cold store version

Applicable in general for the symbols: •

Unfilled symbol – Check / lubrication.

•

Filled symbol – Change.

SERVICE MANUAL

Service / Specific instructions / Traction motor

3.17

Specific instructions Traction motor Preventive maintenance Preventive maintenance is implemented in accordance with the recommended intervals in the service chart.

In some cases, however, exceptions must be made and the intervals shortened in relation to the conditions at the customer, e.g. a severe environment with dust, high humidity levels, or salt, etc.

•

Listen for abnormal noise from the bearings when the motor is run. Check that it does not vibrate abnormally.

•

The motor is blown clean with dry compressed air, or cleaned with a vacuum cleaner. A cleaning fluid should be used to drive out oil and dirt, if oil has leaked from the gearbox into the motor.

•

Check the insulation resistance for the motor, see specification in section 1 for correct value.

Gearbox First service First oil change after 200 hours

•

The first oil change should be made after approx. 200 hours.

•

Use a recommended type of oil, see section 1.

Preventive maintenance Oil level checked during each service

•

The oil level is checked during each service.

•

The guide bearing must be greased at least once a year. New greasing is essential if steam cleaning or high-pressure washing has been carried out.

Note!

Remember to fill up the gearbox after changing the oil or changing the gearbox. See section 5 for procedure.

Note!

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

SERVICE MANUAL

3.18

Service / Specific instructions / Lift chains and forks

Lift chains and forks Check The forks should be checked during each service

For safety reasons the forks should be checked during each service, see "Check list, service inspection" on page 3.7

SERVICE MANUAL

Service / Specific instructions / Hydraulic oil

3.19

Hydraulic oil Hydraulic oil filer change after 500 hours

First service •

Oil filters should be changed after 500 hours.

Intervals After 500 hours of operation: The hydraulic oil filter and air filter to the hydraulic oil tank should be changed after no more than 500 hours of operation. This refers to those types of trucks that have replaceable filters. Clean the suction filter.

After every 1000 hours of operation: Change the hydraulic oil, oil filter and air filter after 1000 hours of operation, or once every year (which ever comes is first).

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

If the hydraulic oil has been contaminated with water (e.g. from cold store) this can be detected in that the oil becomes milky, or smells bad.

It can also be checked with the following simple test: 1.

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

Warning!

Risk for burn injuries on the skin.

2.

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

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

Emergency stop Special emphasis should be placed on the inspection of the emergency stop. Of the contactor tip seems to be worn during a visual inspection, it should be replaced on a preventive basis. Applies to emergency stop SE.

Warning!

The unit should be replaced if the emergency stop has been used in a dangerous situation.

SERVICE MANUAL

3.20

Service / Specific instructions / Recommended replacement

Recommended replacement Hydraulic hoses should be replaced after 5 years, since the rubber in the hose is perishable.

Storage of machines and motors Machines in storage that will not to be used within one month, must be given special attention so that problems do not occur when they are to be used again. Dust, dirt, condensation and moisture caused by large changes in temperature and problems with rust and oxidisation must be prevented. Motors should therefore be protected with waxed paper or the like, and a moisture absorbing material.

SERVICE MANUAL

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2005B

4 Chassis Design and function ....................................................................................................... 4.3 Scope .................................................................................................................. 4.3 Machine housing ................................................................................................. 4.3 Covers and panels ............................................................................................... 4.3 Castor wheel ........................................................................................................ 4.4 Repair instructions ......................................................................................................... 4.5 Covers and panels ............................................................................................... 4.5 Dismantling of panels ..................................................................................................... 4.5

Castor wheel ........................................................................................................ 4.6 Replacing the castor wheel/bearing ............................................................................... 4.6

Battery ................................................................................................................. 4.8 Changing the battery ...................................................................................................... 4.8 Replacing the battery rollers ........................................................................................... 4.8

SERVICE MANUAL

4.2

SERVICE MANUAL

Chassis / Design and function / Scope

4.3

Edition 2005B

4 Chassis Design and function Scope A chassis normally includes the supporting parts of a construction and in the case of a truck the chassis consists of the machine housing, panels and castor wheel.

The straddle lift and load wheel could be considered to be part of the chassis, but since they are part of the mast the instructions for these are to be found in chapter 6, Mast, instead.

Machine housing The chassis on the PLP truck consists of a machine housing. This is where all the truck components, such as the mast, drive unit, and hydraulic system are mounted.

Figure 4.1 Machine housing PLP

Covers and panels The function of the panels is to protect the driver from moving parts, electrical components, oils and fluids, and to protect the components inside from external damage and dirtying.

SM_PLP_04_119002_2005B.fm

SERVICE MANUAL

4.4

Chassis / Design and function / Castor wheel

Castor wheel The caster wheel is a fully turning, non-driven wheel placed under the machine housing.

PLP has two castor wheels.

SERVICE MANUAL

Chassis / Repair instructions / Covers and panels

4.5

Repair instructions Covers and panels The recyclable panels are manufactured of sheet metal and durable plastic.

Dismantling of panels 1.

Loosen the two screws to the side panels (pos 1), from the outside. Remove the panels.

2.

Loosen the plate bolts (pos 2).

3.

To remove the panels pos 3, you must first unscrew the knob on the emergency stop button. Press in the emergency stop. Pick off the small plastic plug that is located in the plastic cover on the battery. Insert a round bar or similar with a diameter of around 3 mm. Turn the emergency stop button until the hole in the axle is identified. Then remove the emergency stop button by turning anti-clockwise.

Remove the two retaining screws and lift out the panels by unfolding the gates to 3/4 and work the panels over the gates.

4.

The battery cover, pos 4 and 5, has four screws that can be accessed by opening the cover. Loosen these and lift off the cover and plastic panel.

4

5

1

3

1

2

Figure 4.2

Clean the panels with soapy water. White impact marks may appear in the case of minor damage to the plastic panels. These marks can be removed by carefully heating with a hot air gun.

SERVICE MANUAL

4.6

Chassis / Repair instructions / Castor wheel

Castor wheel 12 15

17

1

14

13

2 3 16

4

5

6

7 11

8 9

10

8

9

Figure 4.3

Replacing the castor wheel/bearing Dismantling •

Remove the plastic cover from the machine housing.

•

Lift up the machine housing approx. 30 cm, and secure with blocks underneath.

•

Loosen the bolts, pos. 12, see figure4.3.

•

Take out the castor wheel unit and support the fork in a vice.

•

Tap out the retaining pin, pos. 11, drive out the wheel axle, pos. 7, and remove the wheel from the fork.

Note!

Take care of the spacers, pos. 8.

•

Support the wheel in the vice instead of the fork.

SERVICE MANUAL

Chassis / Repair instructions / Castor wheel

•

4.7

Pull out the bearings with a bearing extractor.

Assembly •

Lubricate the wheel bearing seats with grease, and press in the bearings with a suitable drift.

•

Place the wheel fork with the side facing down.

•

Hold the wheel and spacers together, and insert the wheel in the fork.

•

Fit the wheel axle, pos. 7.

•

Tap in the retaining pin, pos. 11.

•

Bring up the complete castor wheel under the machine housing, and fit the screws, pos. 12.

Note!

Check the positioning to make sure the grease cup comes in the right direction.

•

Tighten to the correct torque.

•

Fit the plastic cover and lift down the machine to the floor.

SERVICE MANUAL

4.8

Chassis / Repair instructions / Battery

Battery Changing the battery Work in an area where the old battery can be removed without risk to the environment from battery acid. Wear acidproof gloves and clothes, plus acidproof glasses, to provide protection from burn injuries.

A battery trolley must be used when changing the battery.

1.

Separate the battery plug.

Figure 4.4 Illustration of changing the battery

2.

Release the battery lock.

3.

Roll out the battery onto the battery trolley.

Warning!

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

Replacing the battery rollers 0

1.

Remove the battery.

Warning!

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

2.

The battery rollers are loose in their seats. Lift up the rollers in the back edge, and pull backwards and upwards.

SERVICE MANUAL

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2007B

5 Drive unit Design and function ....................................................................................................... 5.3 Introduction .......................................................................................................... 5.3 Traction motor ..................................................................................................... 5.3 Gearbox ............................................................................................................... 5.3 Repair instructions ......................................................................................................... 5.4 Preparations ........................................................................................................ 5.4 Dismantling the drive unit housing ....................................................................... 5.4 Traction motor ..................................................................................................... 5.5 Storage of traction motor ................................................................................................ 5.5

Gearbox ............................................................................................................... 5.5 Motor mounting .............................................................................................................. 5.6 Changing the wheel studs .............................................................................................. 5.6 Service and fitting of the lower shaft seal on the gearbox .............................................. 5.6 Guide bearing ................................................................................................................. 5.6 Gear collar and drive pinion ........................................................................................... 5.6 Checking the oil level and filling up with oil .................................................................... 5.6 Oil change ...................................................................................................................... 5.6

Drive wheel .......................................................................................................... 5.7 Replacing the drive wheel .............................................................................................. 5.7

Diagnostics and trouble shooting ................................................................................ 5.8 Trouble shooting chart ......................................................................................... 5.8

SERVICE MANUAL

5.2

SERVICE MANUAL

Drive unit / Design and function / Introduction

5.3

Edition 2007B

5 Drive unit Design and function Introduction The drive unit is mounted in a vertically moving assembly containing the brakes, traction motor, gearbox and drive wheel.

PLP is equipped with a technical solution for five-wheel pedestrian trucks, designated Friction Force, which efficiently ensures that an optimum drive wheel pressure is always available.

Friction Force utilises the principle of increasing the force on the load wheel with an increasing effective force on the forks. The load wheel force is transferred via a link system to the vertically moving suspended drive wheel, so that the wheel forces are concentrated there. The suspension also includes compression springs, which make the wheel insensitive to irregularities in the floor and ensure an optimum drive wheel pressure even when the truck is not loaded.

Friction Force also ensures improved ergonomics in that a cushioning effect is also achieved at the load wheel and also by reducing rattling noise in the lifting system.

For technical data regarding component parts, see section 1.

Traction motor The traction motor on PLP is a three-phase induction motor. A pulse transducer is enclosed in the bearing on the non-driving end of the motor and this provides speed return to the traction controller, see section 10.

The motor is mounted directly on the gearbox and the transmission of power takes place via individually adjusted gear wheels.

Gearbox The gearbox is designed to produce the best gear ratio over the speed range of the traction motor.

SM_PLP_05_119002_2007B.fm

SERVICE MANUAL

5.4

Drive unit / Repair instructions / Preparations

Repair instructions Preparations 1.

Separate the battery plug.

2.

Remove the panels on the machine housing, see section 4.

Dismantling the drive unit housing 3

2 1

Figure 5.1

1.

Dismantle the gates. Start with the gas spring.

2.

Release all the electrical connections to the traction motor and brake.

3.

Release the electric panel and fold back.

4.

Release the gas spring to the platform.

5.

Unscrew the eight socket head cap screws holding the traction motor, and lift it out. Protect the motor shaft and the hole in the gearbox, e.g. with rags.

6.

Unscrew the three socket head cap screws holding the motor bed to the gearbox.

Lift out the motor bed.

SERVICE MANUAL

Drive unit / Repair instructions / Traction motor

5.5

7.

Release the two springs pressing down the drive wheel when it is unloaded by completely screwing off the four nuts. Use a long socket.

8.

The two long bolts to the springs must be taken out from underneath. Lift up the truck to a suitable height and secure with blocks. Remove the two bolts.

9.

Release and remove the cable duct on the top of the machine housing.

10. Release the electrical connections to the tiller arm, and release and lift out the complete assembly with steering axle, tiller arm head and guide belt.

11. Release and drive out the two shafts (pos. 1 in fig. 5.1) in the lower link arms as far as is possible. The shafts must not be completely removed.

12. Release and drive out the four shafts (pos. 2 and 3. in fig. 5.1) in the upper link arms.

13. The drive unit housing can now be lifted out from the truck. Mark the position of the gearbox in the drive unit housing before removing the gearbox from the housing.

14. Assemble in the reverse order. Note that the springs should be compressed to 180 mm on PLP 200 and to 156 mm on PLP 250. The length of the springs when unloaded is 203 mm. When the guide belt is to be refitted it is important that the drive wheel is standing straight up when seen from behind, has the wheel nuts to the left, and that the stops on the steering axle point straight down. The zero position of the steering will be incorrect if this is not the case.

Traction motor The traction motor is mounted on the top of the inner ring in the guide bearing, with a total of six screws. When assembling and dismantling the traction motor the contact surfaces between the motor and gearbox must be thoroughly cleaned. It is also important that the pinion teeth are in line with the drive teeth so that the tooth flanks are not damaged.

Storage of traction motor Machines in storage that will not to be used within one month must be given special attention so that problems do not occur when they are to be used again. Dust, dirt, condensation and moisture caused by large changes in temperature and problems with rust and oxidisation must be prevented. Motors should therefore be protected with waxed paper or the like, and a moisture absorbing material.

Gearbox Service work on the gearbox is limited to changing the wheel studs on the wheel and changing the lower shaft seal.

SERVICE MANUAL

5.6

Drive unit / Repair instructions / Gearbox

Motor mounting The motor mounting is screwed in the gearbox with three socket head cap screws. These should be treated with Loctite 243 or the equivalent when fitted.

Changing the wheel studs After removing the wheel stud that is to be changed the threads on the new wheel stud and the threads in the hole should be cleaned from oil and grease. The threads should be treated with Loctite 243 or the equivalent before the new wheel stud is screwed in.

Service and fitting of the lower shaft seal on the gearbox The shaft seal can be removed after removing the protective disc.

The seal seat in the casing and the surface to which the seal is to seal should be cleaned before fitting a new seal. The seal should also be greased before it is fitted. The protective disc is replaced after fitting the shaft seal.

Guide bearing The guide bearing is protected by rubber rings and is maintenance-free as long as not special cleaning has been carried out with a high-pressure jet.

Gear collar and drive pinion The guide gear collar and drive pinion on the gearbox should be greased with standard grease.

Checking the oil level and filling up with oil Oil is poured in through the upper filler screw hole. The correct level is at the lower edge of the hole.

The oil level should be regularly checked to avoid damaging the gearbox.

Oil change The oil is drained out through the lower oil plug hole. The oil can be drained more easily if it is warm.

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

Before screwing in the oil plug again it should be cleaned.

SERVICE MANUAL

Drive unit / Repair instructions / Drive wheel

5.7

Drive wheel Replacing the drive wheel 0

1.

Loosen the wheel nuts.

2.

Lift up the truck so that the drive wheel can rotate freely.

3.

Separate the battery plug.

4.

Turn the drive wheel 45°.

Figure 5.2 Loosen the nuts on the drive wheel.

5.

Remove the wheel nuts.

6.

Replace the drive wheel.

7.

Tighten the wheel nuts to 84 Nm.

8.

Start the truck and test drive in both directions. The wheel must not catch or jam.

SERVICE MANUAL

5.8

Drive unit / Diagnostics and trouble shooting / Trouble shooting chart

Diagnostics and trouble shooting Trouble shooting chart Symptom

Cause

Action

The wheel has a flapping sound when driving.

The tyre has separated due to impact.

1. Change the wheel.

The wheel squeaks continuously when driving.

Bearing is damaged.

1. Replace bearing.

The wheel is flat after long breaks, but becomes round after driving for a while.

The wheel mass has become warm while driving and deforms when parked.

Try a different type of wheel.

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

A “blow out” has taken place due to overheating and changed the molecular structure of the wheel mass.

Change the wheel.

The truck seems to jerk when driving.

Hard foreign object has fastened in the drive wheel.

1. Remove the object or change the wheel.

2. Examine the floor for any irregularities.

2. Inform the driver that string and plastic etc. should be removed daily, and the floor kept clean.

2. See also items above.

The truck jumps at regular intervals, proportional to the speed, when driving.

The wheel is oval.

1. Change the wheel.

2. Check/adjust the brake.

3. See also items above.

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

The wheel has been heated.

Small cracks appear with hard acceleration and reversing.

The wheel has one or more small deformations.

Locking of the brakes so that 1. Remove objects on the floor. the wheel slides, or loose objects on the floor that pre2. Tell the driver to brake vent the wheel from rotating. more smoothly.

Oil on the floor.

Leaking seal around the drive axle.

SERVICE MANUAL

1. Lower the acceleration and reversing rate.

2. Change the wheel if necessary.

•

Replace seal

or: • If there are cracks in the casting the gearbox must be replaced.

Drive unit / Diagnostics and trouble shooting / Trouble shooting chart

Symptom

Cause

Action

Grating noise when accelerating or using the reversing brake.

1. Defective gear wheel in the drive unit.

Check the teeth by removing the cover.

2. Too little oil in the gearbox.

If there are cracks in the casting the gearbox must be replaced.

Grating noise when the truck is lifted up and the drive wheel can rotate freely and the motor rotates.

Faulty bearing in the traction motor.

Dismantle and renovate the traction motor.

The truck rolls "sluggishly".

1. The brakes are applied.

•

Replace brake disc.

If this does not help: •

replace the complete brake unit.

2. The drive unit has seized. If there are cracks in the casting the gearbox must be replaced.

Clicking sound when driving.

Faulty wheel bearing.

Change the wheel.

Clicking sound when driving.

Loose wheel.

•

Tighten the wheel.

If this does not help: •

Change the wheel.

1. Too much slack in control 1. Tighten the control belt, The drive unit pulls at an belt. see Chapter 7. angle which is felt in the tiller arm. This makes it diffi2. The drive unit leans.

2. The bushings in the links cult maintaining the right for the drive unit housing course when accelerating and 3. The machine housing should be replaced. braking. (Applies to maleans. chines without servo) 3. The caster wheels are un4. Drive wheel camber evenly worn. Replace both missing. Or track is worn. caster wheels, or use shims.

4. Replace drive wheel. See also Parts and Service News 2093.

SERVICE MANUAL

5.9

5.10

Drive unit / Diagnostics and trouble shooting / Trouble shooting chart

SERVICE MANUAL

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2003

6 Mast system Design and function ....................................................................................................... 6.3 Lift system ........................................................................................................... 6.3 Repair instructions ......................................................................................................... 6.4 Fork carriage, general ......................................................................................... 6.4 Dismantling the fork carriage .......................................................................................... 6.4

Adjusting the fork carriage ................................................................................... 6.4 Diagnostics and trouble shooting ................................................................................ 6.6 Trouble shooting chart ......................................................................................... 6.6

SERVICE MANUAL

6.2

SERVICE MANUAL

Mast system / Design and function / Lift system

6.3

Edition 2003

6 Mast system Design and function Lift system The truck variants PLP 200 and PLP 250 have low-lifting fork carriages.

SM_PLP_06_119002_2003.fm

SERVICE MANUAL

6.4

Mast system / Repair instructions / Fork carriage, general

Repair instructions Fork carriage, general Dismantling the fork carriage 1.

Separate the battery plug.

2.

Remove the covers over the machine housing.

3.

Release and drive out the four shafts, pos. 1 and 2.

1

2

Figure 6.1

4.

Lift the fork carriage straight up.

Important!

Observe great caution!

Adjusting the fork carriage The truck must stand on a level surface. Lower the forks and check the height from the floor to the top of the forks. The height should be 85-93 mm, with a difference of only 5 mm between the four measuring points, see figure 6.2. If the forks are too high, or too low, this is adjusted with the adjusting screw over the lift cylinder.

SERVICE MANUAL

85 +8 -0

85 +8 -0

Mast system / Repair instructions / Adjusting the fork carriage

Figure 6.2

SERVICE MANUAL

6.5

6.6

Mast system / Diagnostics and trouble shooting / Trouble shooting chart

Diagnostics and trouble shooting Trouble shooting chart 0

Table 6.1 Symptom/Action table Symptom

Possible reason

Action

Play to mast.

Mast rollers not shimmed enough.

Adjust the side supports.

The fork carriage lowers unevenly, jumps.

Side supports adjusted too hard.

Adjust the side supports.

No grease on the mast roller surfaces.

Grease roller surfaces.

No grease on the mast roller surfaces.

Grease roller surfaces.

The fork carriage squeaks.

SERVICE MANUAL

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2007B

7 Steering Design and function ....................................................................................................... 7.3 General ................................................................................................................ 7.3 Steering ............................................................................................................... 7.3 Servo unit (–2005w19) ........................................................................................ 7.3 Servo unit, diagnosis (–2005w19) .................................................................................. 7.4

Servo unit (2005w20–) ........................................................................................ 7.5 Servo unit, diagnostics (2005w20–) ............................................................................... 7.6

Repair instructions ......................................................................................................... 7.7 Cleaning .............................................................................................................. 7.7 Tiller arm head (–2007w27) ................................................................................. 7.7 Replacing ....................................................................................................................... 7.7

Tiller arm head (2007w28–) ................................................................................. 7.8 Dismantling the tiller arm head ....................................................................................... 7.8 Dismantling buttons lift/lower .......................................................................................... 7.9 Dismantling the speed controller .................................................................................... 7.9 Assembly of main cables and brake switch .................................................................... 7.9

Tiller arm (2007w28–) ........................................................................................ 7.12 Dismantling the gas spring ........................................................................................... 7.12

Replacing the steering belt ................................................................................ 7.13 Adjusting the steering belt ................................................................................. 7.13 Adjustment, limit switch ..................................................................................... 7.13 Adjustment, electrical steering ........................................................................... 7.14 Servo steering (2006w15–) ............................................................................... 7.17 Adjusting the steering force .......................................................................................... 7.17 Troubleshooting steering force ..................................................................................... 7.19

SERVICE MANUAL

7.2

SERVICE MANUAL

Steering / Design and function / General

7.3

Edition 2007B

7 Steering Design and function General The steering movement is transferred mechanically from the tiller arm to the drive unit with a drive belt.

Steering The truck is steered by turning the complete tiller arm, which via a drive belt affects the angle of the drive wheel. There is a switch in the arm, which by means of switching off the current and actuating the brake causes the truck to stop when the arm is in its upper and lower end positions. It is therefore only possible to drive the truck when the arm is between these end positions. There is also a belly switch, which stops the truck when pushed in. The purpose of the belly switch it to prevent the operator being crushed between the truck and other objects.

This electronic steering system is designed as a help system for the mechanical steering, which means that the servo assists when the mechanical steering is actuated. The servo unit uses 2 voltage-controlled signals for control and the servo will shut down if one of the signals fails. A red fault indication lamp lights on the servo unit in the event of a simple fault and the servo function will fail to operate. The truck will now operate as a normal PLP without servo.

All sensor inputs are short circuit proof against short circuits to the ± battery. However, the motor connection is not short circuit proof. A contactor is needed in series with the servomotor so that the servomotor can generate voltage itself. Failure to connect the battery and performing a quick manoeuvre and if the generated voltage of the servomotor exceeds 35 Volts will damage the truck's electrical system.

Servo unit (–2005w19) The position indicators emit identical output signals to the servo, which are 6.0 volts in neutral position. The servo will shut down if there is a difference of more than 0.5 volts between the position indicators (red light diodes on PSA Servo box).

The servo has a dead zone of ±0.5 volts around 6.0 volts. Full drive is provided at ±1.7 volts. The dead zone's mid-position can be adjusted ± 0.3V by means of a small hole on the right underside of the PSA servo box (max 300 degree turn).

The servo function can be blocked by an external signal of 24 volts, which is ± 95-degree control; there is a mechanical blocking function at ± 105 degrees. When the servo is blocked the same red light diode lights that indicates incorrectly adjusted position indicator. The limit switch also breaks the contactor to the servo motor.

SM_PLP_07_119002_2007B.fm

SERVICE MANUAL

7.4

Steering / Design and function / Servo unit (–2005w19)

Servo unit, diagnosis (–2005w19) Electric power from battery Table 7.1 2-terminals pin AMP gray

Position

Cable colour

Description

#1

Red

Battery + 16-32V

#2

Blue

Battery - 0V

Electric power motor Table 7.2 2-terminals pin AMP black

Position

Cable colour

#1

Description Motor +

#2

Black 250 mm

Motor -

Sensor 1 Table 7.3 4-terminal minifit pin

Position

Cable colour

Description

#1

Grey

Positive feed sensor 12VDC +-5%

#2

White

Signal sensor

#3

Not connected

#4

Black

0V

Sensor 2 Table 7.4 4-terminal minifit pin

Position

Cable colour

Description

#1

Grey

Positive feed sensor 12VDC +-5%

#2

White

Signal sensor

#3

Not connected

#4

Black

0V

Blocking signal from braking Table 7.5 2-terminal minifit

Position #1 #2

pin

Cable colour Yellow

Description Blocking 16-32V Not connected

SERVICE MANUAL

Steering / Design and function / Servo unit (2005w20–)

7.5

Servo unit (2005w20–) The position sensors must produce identical output signals to the servo, 6.0 Volts in neutral. Where there is more than 1 Volt difference between the position sensors, the servo shuts down (red LED on the PSA servo box).

The servo has a dead zone of ±0.5 Volts around 6.0 Volts. Full drive is reached at 1.9 Volts.

The servo function can be blocked by an external signal of 24 Volts. This signal is controlled by a breaker in the arm that is activated when the arm is in active mode. For older models, an end position breaker can also block the servo function. The same red LED lights when the servo is blocked as the one that indicates an incorrectly adjusted position sensor.

SERVICE MANUAL

7.6

Steering / Design and function / Servo unit (2005w20–)

Servo unit, diagnostics (2005w20–) Power connection from battery Table 7.6 Contact piece X22, 5-pin sleeve AMP

Position

Cable colour

Description

# 1, X22.1

Red/Blue

Battery +24V

# 2, X22.2

Blue

Battery - 0V

# 3, X22.3

Pink/White

Blocking signal +24V

Power connection, motor Table 7.7 Contact piece X22, 5-pin sleeve AMP

Position

Cable colour

Description

# 4, X22.4

Red

Motor +

# 5, X22.5

Black

Motor -

Sensor 1 and Sensor 2 Table 7.8 Contact piece X24, 8 pin minifit

Position

Cable colour

Description

# 1, X24.1

Orange

Positive feed sensor 1, 12VDC +-5%

# 2, X24.2

Green

Signal sensor

# 3, X24.3

Black

0V

# 4, X24.4

Black

0V

# 5, X24.5

-

# 6, X24.6

Orange

Positive feed sensor 2, 12VDC +-5%

# 7, X24.7

Green

Signal sensor

# 8, X24.8

Black

0V

SERVICE MANUAL

Steering / Repair instructions / Cleaning

7.7

Repair instructions Cleaning The tiller arm and tiller arm head are cleaned with compressed air, or by vacuum cleaning. The covers can be cleaned with lukewarm water and a mild soap solution.

Note!

High-pressure washing must not be used.

Tiller arm head (–2007w27) Replacing 1

3

3 3

2

Figure 7.1 Tiller arm head

1.

Loosen the three screws, pos. 3 see Figure 7.1, that secure the upper cover.

2.

Press in the belly switch, pos. 1 see Figure 7.1, and release the cover by carefully pushing it upwards and outwards.

3.

Loosen the two screws, pos. 2 see Figure 7.1.

4.

Loosen the requisite connectors to replace the head.

5.

Assemble in the reverse order.

SERVICE MANUAL

7.8

Steering / Repair instructions / Tiller arm head (2007w28–)

Tiller arm head (2007w28–) Dismantling the tiller arm head 1.

Adjust the arm to its shortest position and unscrew the control lever (only applies to PLP with adjustable arm).

2.

Undo the screws that hold the upper and lower cover together.

3.

Release the snap on clip (A) at the front of the tiller arm head.

4.

Carefully lift up the front section of the upper cover, shown by arrow B. Now move the upper cover backwards, see arrow C. C

B

A

Figure 7.2 Dismantling the tiller arm head

5.

Turn the upper cover to the right. The cover can now hang by the main cable.

Important!

Make sure the programming cable load is not too great.

6.

Assemble in the reverse order.

Important!

Ensure that no cables get jammed when fitting the head.

SERVICE MANUAL

Steering / Repair instructions / Tiller arm head (2007w28–)

7.9

Dismantling buttons lift/lower 1.

Open the tiller arm head as shown in the description “Dismantling the tiller arm head” on page 8.

2.

Dismantle the buttons by releasing the snap on clips from the inside, see Figure 7.3.

Figure 7.3 Dismantling buttons lift/lower

3.

Dismantle the inner section by sliding it in the direction of the axle. Now lift the section out from the top.

Important!

Following dismantling, a new button must be fitted as the snap fasteners may be damaged.

Dismantling the speed controller Important!

Apply the removable thread locking solution, e.g. Loctite 243, to the screws of the speed controller.

Assembly of main cables and brake switch Attaching the tiller arm main cable (PLP with fixed arm): Attach the cable to the control lever head using the cable clip. Pull the cable down to the tiller foot, to the right of the steering shaft. Attach the cable to the machine with cable ties to the cable bar.

Pull the cable from the break switch to the left of the steering shaft and attach to the cable bar using cable ties.

Important!

Ensure that the cables do not chafe against any sharp edges.

Important!

The cables are to have enough slack to ensure that you can lower the arm to its lowest position and turn as far as possible to the left and right without stretching the SERVICE MANUAL

7.10

Steering / Repair instructions / Tiller arm head (2007w28–)

cable. It must be possible to open the top section of the control lever head without the cable being a restriction.

Important!

The main cable must not be of such a length that the programming cable has to take the load when the top part is hanging from the cable.

Attaching the tiller arm main cable (PLP with adjustable arm): Attach the cable using the cable clip in the tiller arm head. Run the cable down through the tiller foot, in front of the steering axle to the forks. Attach the cable in the machine using cable ties on the cable bar.

Important!

The cable should almost be at full stretch when the arm (adjusted in its furthest position) is in its bottom position and is turned as far as possible to the right or the left. If this is done correctly, the length of the cable is adjusted to ensure that it is possible to open the top section of the tiller arm head in such a way that does not put a strain on the programming cable.

Cable routing standard design

Figure 7.4 Cable routing, standard design

SERVICE MANUAL

Steering / Repair instructions / Tiller arm head (2007w28–)

Cable routing optional

2 1 Figure 7.5 Cable routing, optional

Table 7.9 Cable routing, optional Position

Description

1

Smartcard

2

Heat resistance

SERVICE MANUAL

7.11

7.12

Steering / Repair instructions / Tiller arm (2007w28–)

Tiller arm (2007w28–) Dismantling the gas spring

8 14 8

13

12

30 9

7 6 5 29

2 31 32

4 SM_PLP_07015A.eps

3

33

Figure 7.6 Tiller arm

1.

Loosen the screw (14).

2.

Loosen the cam (12) by angling the arm at about 45º and then moving the cam forwards.

3.

Loosen the stop screw (6).

4.

Lift up the rubber damper (31) along the piston at the same time as you angle the tiller arm upwards.

5.

Loosen the gas spring by opening the strap on the ball retainer (32) using a screwdriver. Now pull off the gas spring from the ball screw.

6.

Assemble in the reverse order.

Important!

Apply grease to the ball retainer (32) and to the fork (30).

SERVICE MANUAL

Steering / Repair instructions / Replacing the steering belt

7.13

Replacing the steering belt 1.

Separate the battery plug.

2.

Remove the panels on the machine housing, see section 4.

3.

Release all the electrical connections to the traction motor and brake.

4.

Unscrew the eight socket head cap screws holding the traction motor, and lift it out. Protect the motor shaft and the hole in the gearbox, e.g. with rags.

5.

Unscrew the three socket head cap screws holding the motor bed to the gearbox.

Lift out the motor bed.

6.

Completely unscrew the two bolts holding the belt tensioner in the bottom of the steering axle, and the two bolts holding the steering axle upper bearing.

7.

Replace the belt.

8.

Assemble in the reverse order.

Adjusting the steering belt 1.

Switch off the power.

2.

Roll out the battery.

3.

Slightly release the two bolts holding the belt tensioner.

4.

Adjust the belt with the adjusting screw.

5.

Tighten the two bolts holding the belt tensioner.

Adjustment, limit switch Ensure the following when adjusting the limit switch: •

That the contact breaker is not in a mechanically closed position.

•

That the end position is not actuated before it should be (>95 degrees). This is checked by moving the tiller arm to the right and left in its outer position. The limit switch should only be actuated by >95 degrees of turning.

SERVICE MANUAL

7.14

Steering / Repair instructions / Adjustment, electrical steering

Adjustment, electrical steering An inspection and if necessary adjustments are always to be made following any adjustment to the belt tension. When adjusting the belt tension check and if necessary adjust the voltage level in neutral position on the potentiometers, see point 2.

Measuring the looseness of the tiller arm checks the belt tension. The looseness should be about 30 mm on a machine with servo.

There are several reasons why the steering could have a sluggish feeling.

•

Too much belt tension

•

The steering axle bearing is seized up

•

The axles adjusting the potentiometer voltage, hits the body of the potentiometer.

There are only two ways of adjusting the PSA servo.

Alternative 1 1.

Adjust the dead zone (max 300-degree turn)

Figure 7.7 Adjusting the dead zone

The dead zone can be adjusted by means of a small hole on the right underside of the PSA servo box, using a small slot screwdriver. Undo the lower fixing screw and pull out the servo box so that you can see the screw hole.

Note!

Do not apply too much pressure to the screwdriver when you adjust the dead zone on the PSA servo box.

Adjusting the dead zone clockwise means that the arm moves easier to the left and more sluggishly to the right. Adjust until the actuator arm moves equally freely in both directions.

SERVICE MANUAL

Steering / Repair instructions / Adjustment, electrical steering

7.15

Alternative 2 1.

Ensure that the axles to the potentiometer arms have the same distance on both sides. .

0-2 mm

Figure 7.8 Adjusting the potentiometer

2.

arms

Adjust by undoing 2 screws on the consoles of the potentiometers on the rear of the drive unit housing.

Figure 7.9 Undoing the screws on the consoles

3.

Carefully move the tiller arm a little to the right and left without activating the actuator arm breaker. Stop the tiller arm in the middle of the play that exists prior to moving the driving wheel. Measure the signal from the position indicators, X23.2 and X24.2 to B-.

4.

Adjust one potentiometer at a time to 6.20V ±0.10V.

SERVICE MANUAL

7.16

Steering / Repair instructions / Adjustment, electrical steering

Note!

It is important to adjust both of the position indicators equally e.g. (6.13 and 6.10V) or (5.85 and 5.9V). NOT 5.8 and 6.2V. If it is not possible to achieve 6.0V on both sides because one of the potentiometers is in its limit position, remove or alternatively add a shim (118016).

Figure 7.10 Adding a shim

Figure 7.11 Adjusting the position indicators

•

Left breaker: For higher voltage, turn the potentiometer clockwise.

•

Right breaker: For lower voltage, turn the potentiometer clockwise.

SERVICE MANUAL

Steering / Repair instructions / Servo steering (2006w15–)

7.17

Servo steering (2006w15–) Adjusting the steering force Function: You can adjust the servo steering force by loosening or tightening the guide belt. In general you could say that a looser guide belt gives a greater range of movement for the potentiometer and increases the power to the steering servo motor making the machine easier to control. If more sluggish steering is required, you can tighten he guide belt to the potentiometer to produce a narrower range with less power to the steering servo motor as a result. the guide belt to the potentiometer to produce a narrower range with less power to the steering servo motor as a result.

10

15

20

19

30

35

SM_PLP_07_0011A.eps

33

32

Figure 7.12 Servo steering

SERVICE MANUAL

7.18

Steering / Repair instructions / Servo steering (2006w15–)

Adjusting the guide belt: 1.

Disconnect the battery connector and move the battery sufficiently enough to access the adjuster screw and locking screws from the battery compartment.

Secure the battery so that it cannot roll.

2.

Loosen the two locking screws a little (pos 35, see Figure 7.12) to the belt tensioner and adjust using the adjuster screw (33) to the desired value. As a starting point, the belt tensioner can be adjusted to ensure that it is square with the drive unit housing, figure A, see Figure 7.13

B A C

Figure 7.13 Adjusting the guide belt.

3.

Figure B ( see Figure 7.13) shows the adjustment for a looser belt that gives more steering force power and figure C shows a tight belt that gives less steering force.

4.

The quality of the floor and type of wheel affect the steering force which then needs to be adjusted to new values.

Adjusting the potentiometer: 5.

Connect the battery and measure with a voltmeter between B- and X24.4. The value must be 6V in neutral. In other words the drive wheel is facing forwards and the guide belt does not affect the mechanism to the potentiometer.

6.

To achieve the value of 6V, turn the bracket the potentiometer is mounted in until the value is reached, see Figure 7.14. If the steering is stiffer clockwise, adjust the bracket clockwise. Likewise, adjust the bracket anticlockwise if the steering is stiffer anticlockwise.

SERVICE MANUAL

Steering / Repair instructions / Servo steering (2006w15–)

7.19

Figure 7.14 Adjusting the potentiometer.

7.

Check by turning the tiller to the right and left while reading the voltage. A good symmetry is when steering to the right gives around 8V, steering to the left gives around 4V and neutral 6V.

8.

The quality of the floor and type of wheel affect the steering force which then needs to be adjusted to new values.

Troubleshooting steering force Steering too stiff or too loose.

Is the steering also either stiff or too loose?

Yes First adjust the steering force using the belt tensioner.

If the steering is uneven in any direction or jerky?

No

Yes Adjust the balance of the steering force using the potentiometer.

SERVICE MANUAL

Ready.

7.20

Steering / Repair instructions / Servo steering (2006w15–)

Uneven or jerky steering.

If the steering is uneven in any direction or jerky?

Yes Is the steering also either stiff or too loose?

No

Yes First adjust the steering force using the belt tensioner.

Now adjust the balance of the steering force using the potentiometer.

SERVICE MANUAL

Adjust the balance of the steering force using the potentiometer.

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2006B

8 Hydraulic system Design and function ....................................................................................................... 8.3 General ................................................................................................................ 8.3 Lift ................................................................................................................................... 8.3 Lowering ......................................................................................................................... 8.3

Electric solenoid valve ......................................................................................... 8.3 General ........................................................................................................................... 8.3 Lifting function ................................................................................................................ 8.3 Lowering function ........................................................................................................... 8.4

Hydraulic diagram ................................................................................................ 8.4 Hydraulic diagram PLP ................................................................................................... 8.6

Repair instructions ......................................................................................................... 8.8 Hydraulic system ................................................................................................. 8.8 General rules .................................................................................................................. 8.8 Installation ...................................................................................................................... 8.8 Connections ................................................................................................................... 8.9 Start up ........................................................................................................................... 8.9

Hydraulic oil, changing/draining ......................................................................... 8.10 Requisite equipment: .................................................................................................... 8.10 Procedure: .................................................................................................................... 8.10 Air filter ......................................................................................................................... 8.10 Properties of the hydraulic oil ....................................................................................... 8.11

Motor, hydraulic unit .......................................................................................... 8.12 When should the brushes be replaced? ....................................................................... 8.12 Replacing the brushes .................................................................................................. 8.12 Tips for prolonging the service-life of the motor ........................................................... 8.13

Solenoid valve ................................................................................................... 8.14 General instructions when working with solenoid valve ............................................... 8.14 Solenoid valve, dismantling and assembling ................................................................ 8.16

Installation instruction for pipe couplings ........................................................... 8.16 Diagnostics and trouble shooting .............................................................................. 8.19 Symptom and Action ......................................................................................... 8.19

SERVICE MANUAL

8.2

SERVICE MANUAL

Hydraulic system / Design and function / General

8.3

Edition 2006B

8 Hydraulic system Design and function General Lift The driver activates a switch, which starts the lift motor by means of a contactor. The electric motor drives the hydraulic pump, which pumps hydraulic oil to the lift cylinders.

The hydraulic system includes a relief valve, which limits the maximum hydraulic oil pressure. The pressure of the hydraulic oil is built up when the cylinder goes towards its end position. The relief valve opens if the maximum system pressure is reached and leads the oil from the pump back to the tank. The opening pressure of the relief valve is set at the factory, so that the machine will be able to handle the load it is designed for.

Warning!

The relief valve must only be adjusted by authorised and trained personnel, since it is a safety part. All work with the hydraulic system must be carried out in a pressureless state, and in a clean environment. If the relief valve is adjusted it must be resealed.

Lowering There is a fixed restrictor valve in the hydraulic unit, which regulates the lowering speed by restricting the return flow of hydraulic oil.

Electric solenoid valve General The electric solenoid valve controls the lifting and lowering movements on the truck. The solenoid valve is actuated electrically by the driver by means of a switch.

Lifting function The pump produces a pressure and flow to the lift cylinder. If the lift cylinder is obstructed, or has an excessive load, the oil goes back to the tank through the relief valve.

SM_PLP_08_119002_2006B.fm

SERVICE MANUAL

8.4

Hydraulic system / Design and function / Hydraulic diagram

Lowering function The solenoid valve opens to release the oil from the lift cylinder. When the fork carriage presses down the lift cylinder the oil flow goes through the lowering valve, which regulates the lowering speed.

Hydraulic diagram Table 8.1 List of hydraulic diagrams for PLP Description Hydraulic diagram PLP

Reference 108011

SERVICE MANUAL

Page 8.6

Hydraulic system / Design and function / Hydraulic diagram

SERVICE MANUAL

8.5

8.6

Hydraulic system / Design and function / Hydraulic diagram

Hydraulic diagram PLP

SERVICE MANUAL

Hydraulic system / Design and function / Hydraulic diagram

SERVICE MANUAL

8.7

8.8

Hydraulic system / Repair instructions / Hydraulic system

Repair instructions Hydraulic system General rules Important!

Cleanliness during all work with hydraulic components is of the greatest importance for the operating safety and service-life of the system. The following should be taken into consideration: •

Dirt particles must not get into components.

•

Do not use cloths that release fibres or particles.

•

Only use clean tools.

•

Carefully clean tanks, pipes and hoses before installation.

•

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

•

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

•

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

•

Take into consideration the specified operating data.

•

Do not exceed permitted pressures and volume flows.

•

Do not exceed or go below the specified temperature range.

•

Pay attention to specified electrical voltages and power consumption.

Note!

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

Installation To prevent dirt and corrosion in the hydraulic system all hydraulic components should be provided with plastic plugs in the connections before they are delivered. Only remove these plugs just before the component is to be installed in the machine. Retaining screws and connections must correspond with those on the drawing. Retaining screws should not be tightened with a higher torque than what is specified on the drawing. If such information is missing, the torque should not exceed what is specified in section 1.

SERVICE MANUAL

Hydraulic system / Repair instructions / Hydraulic system

8.9

Connections Couplings should be fitted according to the torque specified in the table in section 1. We recommend couplings with elastic seals.

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

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

Test the function and tightness of the system. Check the oil level. Set the pressure and volume flows slowly to the values they should have. Check the connected measuring equipment regularly, where appropriate. Pay attention to the noise level since abnormal noise implies defects. Test during variable loads that components are correctly fitted, and that the system is tight.

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

SERVICE MANUAL

8.10

Hydraulic system / Repair instructions / Hydraulic oil, changing/draining

Hydraulic oil, changing/draining Requisite equipment: •

New oil, or purifying equipment for the old.

•

A tray to collect the oil in.

Procedure: 1.

Lower down the forks and disconnect the battery.

2.

Remove the panels enclosing the area where the hydraulic unit is placed.

3.

Check how much oil needs to be filled by marking the existing level. e.g. with a strip of tape. Before marking the level the lift cylinder should be run several times to check that the pump does not suck air (screaming noise at the end). If this should be the case the marking should be moved correspondingly so that this does not happen when new oil has been filled.

4.

Remove the cap on the hydraulic oil tank.

5.

Suck up the oil with a pump, and pump over the old oil to a suitable container.

Important!

Avoid spilling oil outside the container. The oil should be handled in accordance with the applicable environmental legislation and local directives.

6.

Fill up with oil to the previously marked level. If possible, filter the new oil when filling. Follow the recommendations in section 1 for the correct type of oil.

7.

The lift cylinder should be run several times to check that the oil level is correct and so that any air will disappear, and also to check for excess oil. Excess oil runs the risk of the oil overflowing.

Wipe up any oil spillage and refit the panels.

Air filter There is an air filter in the refilling plug on the hydraulic tank, which during service/oil change should be cleaned. The filter is cleaned with a suitable grease solvent that will not damage the rubber, e.g. turpentine.

Pull out the filler plug from the tank and remove the red cap fixed with three barbs. Wash the foam rubber filter and blow clean, or squeezze dry with paper. Refit in the reverse order. The filter should be replaced if the foam rubber is damaged.

SERVICE MANUAL

Hydraulic system / Repair instructions / Hydraulic oil, changing/draining

8.11

Properties of the hydraulic oil The hydraulic oils recommended in this manual, section 1, have properties that promote a long service-life and good functionality, and these are the oils that should be used in the truck. The hydraulic oil used in Atlet trucks must comply with Atlet quality requirements:

Important!

Never mix oils of different types or brands! Environmentally adapted oils must not be used without the approval of Atlet if the warranty it to be valid.

•

Smooth action.

•

Long service-life.

•

High viscosity index with wide range of temperature applications.

•

Good low-temperature properties.

•

High filterability.

•

Good air and water separating capacity.

•

Good wear protection.

•

Good oxidation stability.

•

Minimum foaming.

•

Provide protection from rust and corrosion.

•

Good adhesive capacity.

SERVICE MANUAL

8.12

Hydraulic system / Repair instructions / Motor, hydraulic unit

Motor, hydraulic unit If the performance of the electric motor changes it should be inspected internally. One of the most common sources of faults is wear on the carbon brushes in the motor.

The brushes can wear out, or stick in the brush holders. In both cases inadequate contact between the brushes and the commutator can lead to serious damage on the commutator surface.

When should the brushes be replaced?

•

If a carbon brush cannot move freely in the brush holder. To check this the brush holder must be released from the brush rigging. The force from the brush spring should then press out the brush from the brush holder as far as is permitted by the cable.

•

If a carbon brush is approaching the end of its usable length. The length of the brushes must never be less than 10 mm (a new brush has a length of 17 mm). Since this is difficult to measure there is an alternative method. Measure the difference between the cable and the groove in the brush holder. The difference should be at least 1 mm. Even if the difference should be slighter more it is recommended to change the brushes anyway, since their remaining service-life may be shorter than the interval to the next inspection.

Replacing the brushes The repair kit consists of brush, brush holder and spring. They should be installed as follows.

1

3 5 2 4

Figure 8.1

1.

Release the cables from the terminals on the motor (pos. 1 figure 8.1).

2.

Release the through bolts from the rear end on the motor (pos. 2 figure 8.1).

3.

Lift out the electric motor from the truck.

4.

Place the electric motor on the drive end.

SERVICE MANUAL

Hydraulic system / Repair instructions / Motor, hydraulic unit

8.13

5.

Loosen the nuts on the terminals, (pos. 3 figure8.1). If the motor has a return earth the earth connection on the rear end of the motor should also be released (pos. 4 figure 8.1).

6.

Loosen the rear end (pos 5. figure8.1). Make sure that the terminals remain in their positions.

A

1

B

C

2 Figure 8.2

7.

Disconnect all four carbon brushes by releasing the screws, pos. 1, figure 8.2 - A, figure 8.2. Now press each brush set to the commutator. - B, figure 8.2. Remove the brush set from the brush rigging – C. The old brush set is replaced with a new set by the reverse procedure. It is recommended to replace each brush separately to avoid confusion. Make sure that each brush set is replaced with the correct part, i.e. one that has the cable on the correct side. (The service kits consist of two matching pairs of brush sets!)

8.

Tightent the screw, pos. 1 figure 8.2, to approx. 1.3-1.8 Nm.

9.

Replace the terminals in the grooves in the rear end, and replace it back on the motor. Check that there is a washer between the rotor and the end (pos. 2 figure 8.2) and that the attachment is located with a tooth and a slot on the casing and end.

10. Insert the through bolts and replace the electric motor in the truck. Tighten the bolts to approx. 4.8-6.8 Nm. 11. Tighten the terminal bolts to 10-14 Nm (pos. 3 figure 8.1).

12. Replace the cables to the motor terminals.

Tips for prolonging the service-life of the motor •

The rapid wearing of carbon brushes and the commutator is often caused by oil.

Oil or grease is burned by the sparks produced at the brushes, and leaves a residue of abrasive ash. If oil or grease is detected in the motor the reason for this must be eliminated immediately.

SERVICE MANUAL

8.14

Hydraulic system / Repair instructions / Solenoid valve

•

Never overload the motor. Brushes that have been severely overheated expand permanently and can fasten in the brush holders.

•

The service-life of the brushes does not only depend on the loading, but also on how worn the commutator is. The commutator should have smooth, level and greyish black surface. A worn commutator must be machine milled (never use abrasive paper, grindstone or file) to a surface fineness of Ra = 0.8-1.8 µm and a maximum runout of 0.03 mm (with the rotor resting in the bearing seats). The service-life of the commutator is prolonged if it is machined a little and often, rather than seldom and a lot. The minimum diameter of the commutator is 40.8 mm.

•

The motor must not be exposed to full load immediately after changing the brushes.

•

Look for signs of overheating on the windings, dark patches, brittle or burned insulation, and damage to the soldering on the commutator. The electric motor should be replaced if such damage is found.

•

If possible, remove dust and dirt from inside the motor with compressed air.

•

A dirty commutator should always be cleaned with a cloth moistend with petrol (do not used cotton rags since these shred fibres), and carefully blown dry with compressed air.

•

If the bearing cup look as if it has run out of oil (i.e. if there is a lot of oil on the rotor washer or brush holder) lubricate it with a little bearing grease.

Solenoid valve General instructions when working with solenoid valve 1.

2.

Cleanliness •

Dirt particles must not get into components.

•

Cloths must not shed fibres and particles.

•

Tools must be clean.

•

Tanks, pipes and hoses must be carefully cleaned before installation.

•

Welded or hot-bent pipes must be pickled and cleaned before they are built-in

•

The oil tank must be closed and provided with an efficient breather filter that prevents the penetration of dirt.

Sealing compound •

Hemp, cement or sealing tape is not permitted.

SERVICE MANUAL

Hydraulic system / Repair instructions / Solenoid valve

3.

8.15

Operating data •

Do not exceed permitted pressures and volume flows.

•

Do not go beyond the specified temperature range.

•

Pay attention to specified electrical voltages and maximum power consumption.

SERVICE MANUAL

8.16

Hydraulic system / Repair instructions / Installation instruction for pipe couplings

Solenoid valve, dismantling and assembling 1.

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

2.

Place protective paper under the valve and release the electric cables to the valve.

3.

Loosen all the oil pipes connected to the valve and plug them.

4.

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

5.

When fitting, tighten the valve and then the oil pipes.

6.

Adjust the relief valve to the rated weight in accordance with the machine plate.

7.

Seal the setting.

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

The pipe should be cut at right angles by means of a pipe cutter (see figure 8.3 and 8.4), after which it is deburred internally and externally, and carefully cleaned.

Important!

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

!

Figure 8.3 Cut at right-angles!

Figure 8.4 Pipe cutter

2.

Oil the thread and pipe olive (not grease) if this type of coupling is used. Put the nut and pipe olive over the pipe end as shown in the figure. If the pipe olive cannot SERVICE MANUAL

Hydraulic system / Repair instructions / Installation instruction for pipe couplings

8.17

be worked over the pipe end it must absolutely not be enlarged. File down the pipe end instead.

3.

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

Important!

The pipe must not follow round.

4.

The pipe olive will now have gripped the pipe, and no longer needs to be pressed against the shoulder. Complete the fitting with an additional ¾ turn of the nut. A mark on the nut simplifies following the specified torque, see figure 8.5.

Figure 8.5 A mark on the nut simplifies the specified torque

5.

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

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

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

SERVICE MANUAL

8.18

Hydraulic system / Repair instructions / Installation instruction for pipe couplings

6.

After fitting, release the cap nut and check that the pipe olive has pressed up a visible swelling in the area in front of it, see figure 8.6. If not, give it another short turn. It is of no importance whether the pipe olive can still be turned.

!

Figure 8.6 A visible swelling should have formed after tightening

After a visible swelling has formed the nut should be fitted without extension of the U-ring spanner, and without excessive force.

Important!

Refitting: After a visible swelling has formed the nut should be fitted without extension of the U-ring spanner, and without excessive force.

7.

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

H 2H

Figure 8.7 Straight pipe length between bend and coupling

8.

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

SERVICE MANUAL

Hydraulic system / Diagnostics and trouble shooting / Symptom and Action

8.19

Diagnostics and trouble shooting Symptom and Action A number of fault symptoms have been listed in the table below, with a number of possible faults and repair procedures. It is therefore possible for other faults to have occurred in addition to the ones listed.

Table 8.2 Symptom

Possible fault

Action

The lift motor runs, but the fork carriage does not lift.

The lowering valve has jammed and is open.

1. Close the valve.

The lift motor runs, but the fork carriage lifts very slowly.

The machine is overloaded.

Lighten the load.

The relief valve is defective.

Adjust the valve to the rated weight.

A foreign object has partially blocked a hose, hydraulic pipe or valve.

Take apart and clean.

Hydraulic hose has been clenched.

Rearrange the hose and clamp secure.

The oil level is too low in the hydraulic tank.

1. Fill with hydraulic oil.

When the tank is almost full, try with 0.1 litre at a time to avoid overfilling.

The lift motor emits a screeching noise just before the fork carriage reaches the top.

2. Adjust, or remove any dirt from the valve.

2. Find out the reason for the low level, and rectify the fault.

The fork carriage will not lower.

Valve does not open on return because of foreign object in the system.

Dismantle valve and clean.

The fork carriage lowers too slowly.

The lowering valve is dirty or defective.

Dismantle the valve and clean, or alternatively replace defective parts.

The oil filter is blocked and dirty.

Change filter.

Dirt in the fixed restrictor in the hydraulic unit.

Dismantle and clean the dirt from the restrictor.

Oil level too high.

Reduce the oil level to correct level.

The oil foams.

Change the oil with oil that has the correct properties.

Condensation water in oil tank.

Empty the tank of oil and fill with new hydraulic oil to correct level.

Air in the hydraulic system.

Bleed the system via the air cylinders.

Hydraulic oil flows out via the air filter.

The fork carriage rocks when lifting.

SERVICE MANUAL

8.20

Hydraulic system / Diagnostics and trouble shooting / Symptom and Action

Table 8.2 Symptom The hydraulic oil has a bad smell, sulphur.

Possible fault The oil separators in the hydraulic oil are ruined.

Motor oil has been used and caused the hydraulic oil to emulsify with water and then rot.

The hydraulic oil has become too hot.

SERVICE MANUAL

Action 1. Change the oil and filter.

2. Flush the complete system with new hydraulic oil.

1. Change the oil and oil filter.

2. Check the breaking function of the lift stop.

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2003

9 Lift cylinders Design and function ....................................................................................................... 9.3 Introduction .......................................................................................................... 9.3 Lift cylinder .......................................................................................................... 9.3 Dismantling and assembling .......................................................................................... 9.3

SERVICE MANUAL

9.2

SERVICE MANUAL

Lift cylinders / Design and function / Introduction

9.3

Edition 2003

9 Lift cylinders Design and function Introduction The lift cylinder consists of a single-acting hydraulic cylinder, where hydraulic oil is pumped into the cylinder and presses out the piston rod.

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

Lift cylinder Dismantling and assembling 1.

Move the battery out of the way.

2.

Remove the hydraulic hose and hydraulic coupling on the cylinder.

3.

Plug the hydraulic hose to avoid dirt getting into the hydraulic system.

1

Figure 9.1

4.

Remove the plate in the fork carriage (pos. 1 in Figure 9.1). Keep the spacers in a safe place.

5.

Lift out the cylinder.

6.

Assemble in the reverse order.

SM_PLP_09_119002_2003.fm

SERVICE MANUAL

9.4

Lift cylinders / Design and function / Lift cylinder

SERVICE MANUAL

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2008A

10 Electrical System Design and Function .................................................................................................... 10.5 General .............................................................................................................. 10.5 Description of Components .......................................................................................... 10.5 Description of Components and Interface .................................................................... 10.6

Repair Instructions ....................................................................................................... 10.7 General .............................................................................................................. 10.7 Safety Procedures ........................................................................................................ 10.7 Abbreviations ............................................................................................................... 10.8

Battery ............................................................................................................... 10.8 Battery Capacity ........................................................................................................... 10.8

General Handling ............................................................................................. 10.10 Function Keyboard ..................................................................................................... 10.10 Menu Tree – Start-up and Top Level ......................................................................... 10.11

Connectors in Cold Storage Rooms ................................................................ 10.12 Greasing ..................................................................................................................... 10.12

Drive and Valve Controller ............................................................................... 10.13 Connector Traction Motor Controller, Specification .................................................... 10.13

Wiring Diagram ................................................................................................ 10.14 Insulation Resistance ...................................................................................... 10.15 Routine Test ............................................................................................................... 10.15

SERVICE MANUAL

10.2

Main Controller Unit ATC, Handling .................................................................10.15 Menus ......................................................................................................................... 10.15 Settings ....................................................................................................................... 10.17 Total Reset ................................................................................................................. 10.17 Set Truck Type ........................................................................................................... 10.18 Monitor menu .............................................................................................................. 10.18 Traction ....................................................................................................................... 10.18 In/Out .......................................................................................................................... 10.19 Set Options ................................................................................................................. 10.19 Calibrate accelerator .................................................................................................. 10.19 Calibration of lifting and lowering controls (ATC T4 mk2, 2007w28–) ........................ 10.20 Add New Driver .......................................................................................................... 10.21 Change Format of Driver ID and Access Code .......................................................... 10.22 Change Access Code for Local or Atlet Service Menu ............................................... 10.22 Log Functions and Hour Counter ............................................................................... 10.23 Read Hour Counter .................................................................................................... 10.23 Temperature Log ........................................................................................................ 10.24 Error Log ..................................................................................................................... 10.25 Read Error Log ........................................................................................................... 10.25 Clear Error Log ........................................................................................................... 10.26 Performance Parameters ........................................................................................... 10.26 Driver Categories ........................................................................................................ 10.26 Set Driver Parameters ................................................................................................ 10.27 Pin Code ..................................................................................................................... 10.27 Safety Checks ............................................................................................................ 10.27 Speed Limits ............................................................................................................... 10.28 General Functional Description .................................................................................. 10.29 Truck Mode ................................................................................................................. 10.29 Temperatures ............................................................................................................. 10.31 Options ....................................................................................................................... 10.32 .................................................................................................................................... 10.33

ATC Logic ........................................................................................................10.33 Direction Selection ..................................................................................................... 10.35 Brake System ............................................................................................................ 10.36 Lift System ................................................................................................................. 10.36

Download .........................................................................................................10.37 Download of Service Data and Logs to a PC ............................................................. 10.37 Download of "Truck Manager" Statistical Logs to a PC .............................................. 10.37

ATC Connector ................................................................................................10.39 Digital I/Os .......................................................................................................10.39 Digital Inputs ATC ....................................................................................................... 10.39 Digital Inputs TMC ...................................................................................................... 10.40 Digital 24V Outputs TMC ............................................................................................ 10.40

Cold Resistance Values ..................................................................................10.41 Fuses .............................................................................................................10.41 Diagnostics and Trouble Shooting ...........................................................................10.42 Truck Remote ACcess, TRAC .........................................................................10.42 Prerequisites ............................................................................................................... 10.42 Utilization .................................................................................................................... 10.42 Connecting Procedure ................................................................................................ 10.42

Illustrated instructions are attached to the TRAC cable. ..................................10.42

SERVICE MANUAL

10.3

Error Codes ..................................................................................................... 10.43 Error Code Indicating ATC: ........................................................................................ 10.43 Error Code Indicating TMC: ........................................................................................ 10.47 Other Trouble Shooting .............................................................................................. 10.50

Appendix 1, Summary menu tree ............................................................................. 10.59

SERVICE MANUAL

10.4

SERVICE MANUAL

Electrical System / Design and Function / General

10.5

Edition 2008A

10 Electrical System Design and Function General Description of Components 5

6 4

2

1 3

Figure 10.1 Components

1.

Drive motor, TM.

2.

Pump motor, PM.

3.

Traction motor controller, TMC.

4.

Emergency stop push button.

5.

ATLET truck controller, ATC.

6.

Battery plug.

SM_PLP_10_119002_2008A.fm

SERVICE MANUAL

10.6

Electrical System / Design and Function / General

Description of Components and Interface The ATC system consists of a keyboard (pos. 1), display (pos. 2) and an ATC card (pos.

3).

3 1

2

Figure 10.2

SERVICE MANUAL

Electrical System / Repair Instructions / General

10.7

Repair Instructions General Safety Procedures Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle.

•

The drive wheel should always be lifted up free from the floor during service work to prevent the vehicle from moving.

•

The battery plug should be pulled out before working on the electrical system. The battery plug may only be connected while trouble shooting, and when the greatest of care is exercised, (with the truck raised).

•

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

•

All metal objects such as watches, chains, spectacles 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.

•

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.

Warning!

Working with electrical vehicles can result in personal injury.

Electronic Controllers •

All the electronic controllers in the truck have multiple safety systems.

•

When replacing or repairing the electronic controllers, or removing cables, the battery should always be disconnected.

Important!

Incorrectly connected battery cables can destroy the electronic controllers.

Warning!

During all work on the truck the drive wheel must be lifted up from the floor to prevent accidents occurring.

After the power has been disconnected to the controller and work or trouble shooting is to be conducted, there can be residual voltage in the capacitors for a few minutes. For this reason observe care when working with current-carrying tools during this period.

SERVICE MANUAL

10.8

Electrical System / Repair Instructions / Battery

Abbreviations AC

Alternating Current

ATC

ATLET Truck Controller

B+

Battery positive

B-

Battery negative

BDI

Battery discharge indicator

CAN

Controller Area Network

DC

Direct Current

ELCB

Electronically load compensated brake

EPS

Electric Power Steering

PSA

Powered steering assistance

TMC

Traction Motor Controller

WG

Wire Guidance

Battery 0

Battery Capacity 100%

50%

90%

40%

80%

30%

70%

20%

60% Figure 10.3 Battery capacity

The battery capacity is shown to the left on the bottom row on the display. Measurements are fully controlled by software, and no further electronics are required. The capacity is measured by measuring the battery voltage.

When the battery capacity gets too low the battery capacity value starts flashing and a buzzer is actuated.

SERVICE MANUAL

Electrical System / Repair Instructions / Battery

10.9

When battery capacity reaches 20%, a lift lock out occurs within 3 minutes of active time and error code E50 will be logged.

Battery capacity %

Unloaded pole voltage

Acid density g/cm3

0

22.92

1,070

10

23.20

1,093

20

23.47

1,116

30

23.75

1,139

40

24.03

1,162

50

24.30

1,185

60

24.58

1,208

70

24.85

1,231

80

25.13

1,254

90

25.41

1,277

100

25.68

1,300

In order to carry out a complete battery discharge indicator (BDI) adjustment, the following procedure has to be performed: 1.

Connect a voltmeter directly to the B+ and B- poles of the battery.

2.

Power up the truck and enter “ATLET menu => Settings => Battery => Calibrate”.

Key in the value from the voltmeter by using the keyboard. For example if the voltage 25.2 V is read from the voltmeter, key in 252.

3.

Enter (ATLET menu => Settings => Battery =>) “Stepdown hi”. This parameter (0-9) decides how quickly the BDI reduces the indicated level when the battery has been recently charged.

• If the indicator does not indicate 100% after a full recharge cycle, or drops too quickly in the range 100%-60%, this parameter should be decreased.

• If the indicator drops too slowly in the range 100%-60%, this parameter should be increased.

4.

Enter (ATLET menu => Settings => Battery =>) “Stepdown lo”. This parameter (0-9) decides how quickly the BDI reduces the indicated level when the battery is close to becoming discharged • If the indicator drops too slowly in the range 60%-20%, this parameter should be increased.

• If the indicator drops too slowly in the range 60%-20%, shows too high a battery status, or the truck stops due to under voltage alarms, this parameter should be increased.

SERVICE MANUAL

10.10

Electrical System / Repair Instructions / General Handling

General Handling Function Keyboard The keyboard is used for driver identification, settings, and for diagnostics. The keyboard consists of 12 keys, which have different functions depending on which position the system is in.

Function in Key:

Input mode:

Operational mode:

Service mode:

Enter a zero.

-

-

Enter a one.

-

-

Enter a two.

Switch between creep speed and full speed.

Step one step down in the menu tree.

Enter a three.

-

-

Enter a four.

-

Step one step to the left in the menu tree.

Enter a five.

-

-

Enter a six.

-

Step one step to the right in the menu tree.

Enter a seven.

-

-

Enter an eight.

Set the truck to full speed.

Step one step up in the menu tree.

Enter a nine.

-

-

-

Used for input to the level selector and to change the system status.

Steps to the upper menu level loop if pressed during input in the upper level.

SERVICE MANUAL

Electrical System / Repair Instructions / General Handling

10.11

Function in Key:

Input mode:

Operational mode:

Service mode:

Used to accept the shown value.

Used to confirm a selected level in the level selector.

Used to select the shown menu alternative.

Function key combinations A “monitor menu” can be obtained if the keys are pressed down at the same time in the Operational mode.

Menu Tree – Start-up and Top Level

1sec OR

System off (no power supply)

Time-out timer elapsed

27-nov-97 10:16 standing by...

Time-out timer elapsed

Power on shutting down...

ATC T4 model

OR

v1.00 1sec

Valid ID + Belly button

Operator ID: ?

Horn Button

Valid code

Local Code:

ENT

????

Operational Mode

Local Menu Tree

2sec

Invalid code

Invalid Code:

2sec

Horn Button

Valid code

ATLET Code:

ENT

????

Horn Button

Settings ENT

Figure 10.4 Menu tree

SERVICE MANUAL

ATLET Menu Tree

Settings Menu Tree

10.12

Electrical System / Repair Instructions / Connectors in Cold Storage Rooms

In Operational Mode If the [i] key is pressed for one second the truck will go to the “stand-by” mode. The changeover is confirmed by a peep.

In Stand-by Mode If the [i] key is pressed for less than two seconds the truck will go to the “operational mode” without asking for a PIN code. If the [i] key is pressed for one second the truck will return to the upper level and ask for an operator ID. There is no reason for the operator to release the [i] key to log out directly from the operational mode.

Connectors in Cold Storage Rooms 0

Greasing Kryotox grease, ATLET part number 110781, should be applied in all electrical connectors. The hand pump, part number 110782, should be used in order to do this. The grease should be applied to the contact surfaces when the connectors are drawn apart. The connectors are then reconnected and the grease is pressed from behind into the connector housing so that it is filled. All blocks that have more than one cable are considered to be connector blocks. Flat pins protected by some form of sheath should not be greased.

SERVICE MANUAL

Electrical System / Repair Instructions / Drive and Valve Controller

10.13

Drive and Valve Controller 0

Connector Traction Motor Controller, Specification The traction motor controller has two connectors with I/Os for valves, sensors, change-over switches and programming tools, etc.

Each connector pin is specified below with, where appropriate, the voltage level in connected condition.

11

1

20

10

X6

Connector X6 (figure shows connector from the cabling side).

Table 10.1 Connector X6 traction motor conntroller AC1 Pin

Description

Comment

X6.1

Controlling of Main contactor.

Controlled to B-.

X6.2

Supply to Main contactor.

+24V

X6.3

Controlling of electric brake.

Controlled to B-.

X6.4

Controlling of pump contactor.

Controlled to B-.

X6.5

Supply to pump contactor/horn.

+24V

X6.6

Controlling of horn.

Controlled to B-.

X6.7

CAN communication.

CAN Low.

X6.8

-

-

X6.9

Pos. supply to drive motor encoder.

+12V

X6.10

Neg. supply to drive motor encoder.

B-

X6.11

Controlling of lowering valve.

+24V

X6.12

Neg. supply to lowering valve.

B-

X6.13

Signal input temp. sensor.

X6.14

-

-

X6.15

-

-

X6.16

+12V supply to HVC.

+12V (Not used as std.)

X6.17

CAN communication.

CAN High.

X6.18

-

-

X6.19

Input A from drive motor encoder.

Synchronises the motor movement with pulses from the encoder.

X6.20

Input B from drive motor encoder.

Synchronises the motor movement with pulses from the encoder.

SERVICE MANUAL

10.14

Electrical System / Repair Instructions / Wiring Diagram

Connector X5 (figure shows connector from the cabling side).

7

1

12

6

X5

Table 10.2 Connector X5 traction motor controller AC0 Pin

Description

Comment

X5.1

Supply from F3 fuse.

+24V

X5.2

Joint supply to all digital inputs.

+24V

X5.3

Input from brake switch.

Closes in upper and lower arm position.

X5.4

-

-

X5.5

Input from gate switches.

Closes with the gates in upper position.

X5.6

Input from platform.

Closes with the platform down.

X5.7

Input from lift stop switch.

The lift stop switch breaks at lift stop.

X5.8

Input from platform.

Closes when the platform is up.

X5.9

Input from fixed platform switch.

Closes when standing on the platform.

X5.10

-

-

X5.11

-

-

X5.12

-

-

Wiring Diagram All the wiring diagrams can be found in a separate “Wiring diagram manual”, contact Atlet for further information.

The relevant wiring diagrams are specified in the table below.

Table 10.3 Description

Machine

Reference

Document code

Wiring diagram

PLP

108007 (–2005w17) 118270 (2005w18–) 118222 (2007w28–)

Circuit diagram

PLP

108186 (–2005w17) 118275 (2005w18–)

SERVICE MANUAL

Electrical System / Repair Instructions / Insulation Resistance

10.15

Insulation Resistance 0

Routine Test You must first disconnect the connectors (plugs) before the truck is insulation tested in order to protect the controllers and other electrical components on the truck. This is because damage can occur, which will shorten the life of component parts. In the event of large insulation errors it is appropriate to use a universal instrument until the error has been found and then make a final insulation test.

This applies to all electronic units on the truck.

Warning!

The instrument has a dangerous voltage across the measuring terminals. Do not touch the terminals during testing.

Routines for insulation testing of all truck models.

1.

Take out the insulation measurement instrument.

2.

Set the test voltage to 100 volt.

3.

Pull out the battery plug. 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 plus pole on the electrical panel plug.

5.

Press the start button and wait until the display has stabilised, then release the button and read-off the value on the display. The approved value on 24 volt machines should be at least 24000 Ω , (24 k Ω ).

6.

Let the earth lead remain attached to the chassis and connect the other lead to the minus pole on the electrical panel plug. After this repeat point 5.

Main Controller Unit ATC, Handling 0

Menus When starting the ATC system there are four different basic menus the user can select.

The user navigates between these different menus by means of the [i] key as shown in fig.

Certain of the menus are protected by a password.

Operator ID: ? i O

SERVICE MANUAL

10.16

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

Local code: ???? i O ATLET code: ???? i O Settings

Navigation in the menus takes place by means of the keys on the keyboard. The keys four and six are used to step up and down, and keys two and eight to step from side to side.

The arrows on the display show the possible directions.

The enter key is used to go into the submenus. To leave a selected menu, use the Exit selection together with the enter key. One refinement is that the horn key can be used as an escape key. It can also be used to step back in the menus to the Exit position. This function can also be used to cancel an initiated parameter change.

The menus are divided into three levels, as follows: Operational This menu is used to log into the Operational mode. Logon takes place by selecting driver ID, entering a password, and finally using the safety switch as an enter key. In the Operational mode it is possible to use the truck and all its functions.

Local Service In the Local Service menu it is possible to change passwords for local service, add and remove drivers, and set the time/date, LCD contrast, and key sound. Certain statistical functions are also available here. A password is needed to access the Local Service menu.

Atlet Service Atlet Service includes all the functions used by Atlet authorised service personnel. A password is needed to access the Atlet Service menu. The Atlet Service menu is built up as shown in fig.

ATLET menu: < Exit

>

ATLET menu: < Options

>

ATLET menu: < Settings

>

ATLET menu: < Tests

>

ATLET menu: < Calibrate

>

ATLET menu: < Logs/Counter

>

ATLET menu: < Set access

>

SERVICE MANUAL

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

ATLET menu: < Total reset

10.17

>

•

Exit – selected to exit the Atlet menu.

•

Options – possibility to set the options available for the truck.

•

Settings – possibility to set driver parameters, hydraulic parameters and battery parameters.

•

Tests – tests I/Os.

•

Calibrate – possibility to calibrate inputs.

•

Log/Counters – possibility to read and clear temperature log, error log, and hour counter.

•

Set access – possibility to add drivers, and set passwords for Atlet and local service.

•

Total reset - Possibility to restore all settings, options, users, calibrations and logs to default values.

Settings Under the settings menu it is possible to select the language shown in the display. Swedish, English, French, and a “custom” language can be selected. It is possible by using a PC and a special program to add on a “custom” language.

Total Reset In the Total reset menu it is possible to restore all settings, options, users, calibrations and logs to default values.

•

Exit: Exits the Total reset menu and performs a restart of the system. Note that the command means leaving the Atlet menu and performing an actual restart of the system.

•

All Users: Clears all users. The default user will be set instead. Also the Atlet code and the Local code will be set to the default codes.

•

Options: Restores all options to default values.

•

Settings: Restores all settings to default values.

•

Calibration: Clears all calibrated values. A new calibration must be performed to make the truck work again.

•

Logs: Clears all logs. Hour meters will not be cleared.

SERVICE MANUAL

10.18

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

Set Truck Type After clearing all settings or installing a new ATC, the truck type has to be set. When powering up the truck again the ATC will automatically open a menu asking which truck the ATC will be used in.

PLP 200 PLP 250

<-

Scroll to the desired truck type and press enter. If the wrong type is selected, reset all settings in the Reset menu and try again.

Monitor menu By pressing the enter and 7 key at the same time it is possible to access the Monitor menu from the Operational mode. The Monitor menu shows the speed, power consumption, motor temperature and TMC temperature.

Monitor menu Traction Monitor menu Pump Monitor menu Steering Monitor menu Wire guide Monitor menu In/Out

Traction Under the Traction menu it is possible to control the motor speed in real time and the current consumption or motor and TMC temperature.

C: 025 degC M: 027 degC 1800 RPM 56 A

Pump: Not relevant for PLP. Steering: Not relevant for PLP. Wire guide: Not relevant for PLP.

SERVICE MANUAL

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

10.19

In/Out Under In/Out it is possible to check all inputs to ATC, TMC and HVC in real time. It is also possible to check the ATC internal interlock functions. The function to check the inputs is built up as shown in fig: ATC inputs:

TMC inputs:

HVC inputs:

EPS inputs:

ATC in/out:

Note that the truck is in Operational mode when the Monitor menu is shown. In other words the truck can be driven, and therefore it is appropriate to block it up in accordance with the safety instructions.

Set Options There are several different options under option. They are used to explain to ATC which accessories the truck is equipped with. Further information on which options are available and their function can be found under "Options" on page 10.32.

The option name and which status the option has (off or on) is specified in the first bar in the display. Setting an option is done as follows: 1.

Step forward to the option to be set, and press enter.

Transp indic: no 0:no 1:yes

2.

Press the 0 key to switch off the option, or 1 to set it.

Transp indic: yes New value saved!

Calibrate accelerator Under Calibrate it is possible to calibrate the accelerator. This is done as follows: •

Select accelerator, and press enter.

CALIBRATE: Accelerator

•

v^

Leave the accelerator in neutral, and press enter.

Release throttle and press ENT

SERVICE MANUAL

10.20

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

•

Apply maximum acceleration in both directions without pressing hard to the end position, and then press enter.

Go to end points and press ENT

•

The display shows if the calibration was successful or not. (only Software 2.23–) Ok! Press ENT Not successful!

Press ENT

•

The calibration is now finished. A window is shown where it is possible to test the response of the accelerator. Press enter to end.

Signal check: 2.3V Out: 064%

Important!

The accelerator must be calibrated at each service.

Calibration of lifting and lowering controls (ATC T4 mk2, 2007w28–)

Important!

The lifting and lowering controls must be calibrated both at ON/OFF and proportional adjustment.

1.

Open the Atlet menu => Calibrate => Lift/Lower. The following display appears: Release lift press ENT

2.

Check that there are no controllers activated. Now press ENT. The following display appears.

Order full raise press ENT

3.

Press lift fully down on the right lift and lower control. Now press ENT.

4.

The following display now appears.

Order full lower press ENT

Press lower fully down on the right lift and lower control. Now press ENT. 5.

The display shows if the calibration was successful or not. (only Software 2.23–) Ok! Press ENT

SERVICE MANUAL

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

10.21

Not successful!

Press ENT

6.

The following display appears: Signal control: x.xV Out: xxx%

You can now use this menu to check that the calibration is correct. Signal check should give the following values: •

When lift is activated: 4.7V (± 0.1V)

•

Neutral (control not activated): 2.7V (± 0.1V)

•

When lower is activated: 0.6V (± 0.1V)

Press ENT. 7.

Repeat the same calibration procedure for the left lift and lower control by selecting Channel 2, and follow steps 1-5. Exit by pressing ENT.

8.

Leave the Atlet menu by going to Exit and pressing ENT.

9.

Loosen the battery and then restart the truck.

10. Perform a function test of the lift and lower function.

Add New Driver New drivers can be added in the menu Set Access. Select Operator to add new driver.

•

Select new/change and press enter.

OPERATOR: New/change

•

v^

Write in the driver ID to be changed/added.

Operator ID: ?

•

Select the driver category the driver is to belong to.

Operator categ:3 ?

•

Select the code applicable for the driver. If the code or category is to be changed for an existing driver, the code associated with this driver ID must be specified first.

New code: ????

•

To verify the code it must be entered one more time.

Verify new code: ***?

SERVICE MANUAL

10.22

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

•

Press enter to end.

OK! Press ENT

Change Format of Driver ID and Access Code In the submenu Set Access there is a function to set the number of digits in the driver ID and access code. Both these can be set from between one to seven digits. Note that drivers with longer codes will not be able to logon if the number of digits is reduced! On the other hand if the number of digits is increased the requisite number of zeros will be added to existing, shorter codes.

•

The format of code/ID is changed in Set Access => Operator => Format.

OPERATOR: Format

•

v^

A warning in two parts is shown. Press 2 to see the second part of the warning.

Continue by pressing 1.

CAUTION! Reduced length may lead

to lost entries 0:escape 1:go on

•

Change the length of ID or Code.

ID length:

5 v

Code length:

•

4 ^

Step out by pressing a four, or the horn key.

Change Access Code for Local or Atlet Service Menu The codes for both Atlet and Local service can be changed in Set Access. This is done in the same way for both, as follows: •

Select Set Access => Local, and press enter.

SET ACCESS: Local

•

v^

Specify the valid code.

Old code: ****???

•

Write in the new code.

New code: ???????

•

Verify the new code.

Verify new code: ****???

SERVICE MANUAL

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

•

10.23

Press enter to end.

OK! Press ENT

Log Functions and Hour Counter There are two different log functions in ATC, error log and temperature log. Both can be read and cleared in Atlet Service.

There are also a number of hour counters and these can divided up into two categories, total time and trip time. Both can be read in Atlet Service, but only the trip category can be cleared. The times measured are: •

Active time – the time the truck is used actively, or in other words the total of travel time and pump time.

•

Log time – the time the system has been logged on.

•

Travel time – the time the drive motor has been used.

•

Pump time – the time the pump motor has been used.

The hour counters can also be read in external units, e.g. a TMC or HVC. The total hour meters can be set in Atlet menu => logs/counters => set hour mtrs. Note that the total hour meters only can be set to a higher value than the existing. There will not be an error message if a lower value is set, but the new value will not be saved.

Read Hour Counter •

Select Hour counters under Logs/Counters.

LOGS/COUNTERS: Hour meters v^

•

Select Trip, Total or External.

HOUR COUNTER: Total v^ HOUR COUNTER: Trip v^ HOUR COUNTER: Read external v^

•

Navigate between the four different hour counters.

TOTAL pump: 00001.246h

•

Step back with the 4 key or with the horn key.

SERVICE MANUAL

10.24

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

Temperature Log The temperator log registers temperature measurements from the TMC in five different temperature intervals. The log saves the number of hours the different temperatures have been measured. See fig: Table 10.4 TMC Temp. ranges:

Hours (the numbers are examples)

-40°C

436.53 h

41-50°C

271.28 h

51-60°C

42.74 h

61-70°C

3.61 h

>71°C

0.00 h

SERVICE MANUAL

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

10.25

Error Log ATC has an error log system that logs external and internal errors. External errors are errors that external units detect and report to ATC. Internal errors are errors that ATC detects itself. The error code, description of the error, date and time, are saved in the error log.

The error log function is based on four error classes: •

A – Shown in the display and saved in the log. Only cleared after it has been read.

•

B – Shown in the display and saved in the log. Cleared when the error has ceased.

•

C – Saved in the log. Not shown in the display.

•

Warning – Gives a text warning. Certain warnings are logged.

In addition to being shown in the display, also indicates an error through an audible signal. The signal is repeated every other minute as long as the error/warning is shown in the display. The warning is shown in the full top bar on the display, while the error is shown in the second bar position 5-8.

The error log is divided into primary and secondary faults. A secondary error is an error that occurs 2 seconds after the first error occurred. If the last primary error is repeated without any other error occurring, this error will not be logged separately in the log. It will be added to a counter in the log of the last error instead.

Example of how the error log works: Primary Log

Secondary Log

01:030122 07:49+ Traction system Low voltage #3 030215 18:09

+01:030122 07:49 Traction system No communication +01:030122 07:49 Valve system No communication

The fault “Traction system, Low voltage” has occurred three times. The first time at 07:49 220103 and the third time at 18:09 150203. There are two secondary faults associated with the first fault, which are shown by the plus character after the time 07:49.

Read Error Log •

The error log is opened with Log/Counters => Error log.

ATLET MENU: < Logs/Counters

>

SERVICE MANUAL

10.26

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

•

The primary faults in the error log are navigated with the 8 and 2 keys. Information is read from the error log as follows: Number in errorlog

Error code

13: E105 030221 12:04:26 Date when error occurred

Time when error occurred

Error description

Traction system no communication Number of times the error has been repeated

#015 occurred: 030402 12:27:15 Date when latest error occurred

Time when latest error occurred

Figure 10.5

•

The [i] key is used to access the secondary log. The secondary errors can then be navigated with the 2 and 8 keys.

Clear Error Log •

To clear the error logs, select Logs/Counters => Reset.

LOGS/COUNTERS: Reset v^

•

Select Error log.

RESET: Error log

•

v^

Select Yes. Reset error log?

0:no 1:yes

Performance Parameters The performance parameters in ATC are divided into two levels, machine parameters and driver parameters. The machine parameters represent the basic setting of the machine.

They are preset at the factory and can only be changed by using a special PC program.

The driver parameters are percentages of the machine parameters.

Driver Categories The software in ATC supports four different driver categories. These are used to give different drivers difference performances. One example is the possibility to have a category SERVICE MANUAL

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

10.27

for experienced drivers and one for beginners. All driver IDs must be associated with a driver category.

Parameter

Description

Limits

Fwd Speed

Maximum speed forward

20-100%

Rev Speed

Maximum speed in reverse

20-100%

Tract Accel

Acceleration

20-100%

Cutback 1

Creep speed

0-90%

Cutback 2

Not used

-

Tract Curr

Current limit

20-100%

Rdc brake

Braking torque for reducer brake

0-100%

Neut brake

Braking torque for neutral position brake

0-100%

Rev brake

Braking torque for reversing brake

50-100%

Brake pedal

Braking torque for the ELCB brake

50-100%

Set Driver Parameters •

Select Settings => Performance. Select the category the driver parameters are to be changed for.

PERFORMANCE: Op category 1 v^

•

Navigate amoung the different driver paraemeters with the 2 and 8 keys. Press enter to select parameter.

Cutback 2

•

20% v^

Write in a new value and press enter.

Cutback 2 25% New value saved!

Pin Code ATC uses a pin code instead of a key switch. Each driver is defined with a unique ID number. A pin code is linked to each driver ID, which can be 1-7 digits in length. Up to 100 driver IDs can be saved. The driver ID and code are used together to access the truck, thereby replacing the key switch.

Safety Checks When logging into the truck there is a safety check of the brake switch, lift system, belly button switch and speed controller. The lifting and speed controller should be inactivated when logging on and the brake switch should previously have been in neutral position. If any of these safety tests fail a warning is shown in the display, with a request to reset the

SERVICE MANUAL

10.28

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

activated control to neutral position. Depending on which control is activated an interlock function will be actuated to prevent the use of certain of the truck functions.

Warning text in display

Cause

Interlock function actuated

Release Throttle

The speed controller is actuated during logon. This warn- Speed interlock ing can also be shown if the steering arm is moved to operational mode with an excessive throttle.

Release Tiller

The brake switch was not in neutral position during startup.

Safety interlock

Release controls

One of the keys for lifting/lowering was actuated during logon. Also shown if more than one lifting/lowering control is actuated simultaneously.

Lift interlock

Release controls

The belly button switch has returned to neutral position after logon.

Safety interlock

Interlock function

System in the truck obstructed

Speed interlock

Drive system

Safety interlock

Drive system

Lift interlock

Lift system

Speed Limits In ATC there is a way of achieving a reduction in speed during the operation of the truck called creep speed. Creep speed is selected by switching with the 2 key between creep speed and full speed (key 8 to go straight to full speed). The actual position is shown in the display with a symbol representing a tortoise or a hare.

Figure 10.6

For safety reasons the maximum speed is decided by the positions of the gates and the platform. See below for a description of the gates and platform states.

Gates out

Platform up

Driver on platform

Allowed speed

0

0

0

No travel allowed

A

0

0

1

6

B

0

1

0

6

C

0

1

1

Fault state

1

0

0

No travel allowed

D

1

0

1

Full speed

E

SERVICE MANUAL

see fig.

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

1

1

0

No travel allowed

1

1

1

Fault state

A

B

C

D

E

F

F

Figure 10.7

General Functional Description For the truck to be in neutral position the following is necessary: •

The tiller arm must be raised.

•

The drive wheel must point straight forwards.

•

Forks in bottom position.

•

Battery plug disconnected.

•

Truck in room temperature (20°C).

•

Safety gates are in upper position.

•

Platform is in upper position.

•

Emergency push button is in its upper position.

Truck Mode The truck can be in four different modes: •

OFF: Voltage disconnected.

SERVICE MANUAL

10.29

10.30

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

•

Logged on/Operational: To be compared with the battery plug connected and the key in the lock, key in on position.

•

Logged off: To be compared with the battery plug connected but the key removed.

•

Standby: To be compared with the battery plug connected and the key in the lock, but in off position.

Off Connect battery plug

Remove battery plug

Logged off

Held down for 1s

Pin plus Bellybutton

Standby

Logged on Held down for 1s

Figure 10.8

In Operational mode all the truck functions such as lifting/lowering and travel can be used. Logon with ID and pin code is required to access the Operational mode. In the Operational mode the driver can utilise a lot of information via the display, such as date, time, battery status, error codes and warning messages, etc.

Time

Date

27-nov-97 ^

10:16 2652h Hourmeter

Battery indicator

Full speed/creep speed symbol

Field for error codes

Lift stop indicator Figure 10.9

•

Date - shows ATC date.

•

Time - shows ATC time.

•

Field for error codes – an error code is shown when an error occurs. When a warning is shown it is shown in the full upper bar instead.

SERVICE MANUAL

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

10.31

•

Symbol for creep speed/full speed - shows if the truck is in full speed or creep speed mode.

•

Hour counter – shows active or logged on time, depending on which selection was made in the options menu.

•

Battery indicator – shows battery status. When 20% battery status is reached the lift system ceases to be available.

Temperatures The TMC measure temperature and sends, if necessary, a warning to the ATC. The temperatures measured are the internal controller temperature and the traction motor temperature. The traction motor temperature is only measured in two steps; over and below 125°C. If a value greater than 125°C is measured the TMC reduces the current and the warning “Motor temp high“ is presented on the display.

The internal controller temperature is measured and handled in two steps. If the temperature is over 75°C the TMC reduces the maximum current. If the temperature is over 100°C the current is reduced to zero and the truck stops. With a controller temperature over 75°C the warning “Ctrl temp high“ is presented on the display.

SERVICE MANUAL

10.32

Electrical System / Repair Instructions / Main Controller Unit ATC, Handling

Options Option

Description

Lift limit

Lift stop for the fork lift. Stops the pump when the lift stop switch is actuated.

The lift stop is connected to a digital input on TMC.

Restart

Restart of the fork lift, activated by pressing 2 on the keypad.

Safety syst

Safety system S3 (only PP* servo). When the safety system is enabled the speed is reduced during cornering. The safety system is a part of Fleet Management.

Effici log

Efficiency log. Included in Fleet Management.

Impact sens

Collision sensor. Included in Fleet Management. The collision sensor is purely software based. The speed is monitored, and sudden and rapid reductions in speed are interpreted - as different degrees of colliding. *Log level -Setting for logging collisions. *Warning level -Setting for collisions that give a warning on the display. *Horn level -Setting for collisions that activate the horn. *Stop level -Setting for collisions that stop the truck. *Supervis level -Setting for collisions that require the truck to be unlocked using a code.

Damage rep

Damage log. 10 seconds after logging the truck reverts to crawl speed and the driver receives a number of questions about any damage. If the driver answers no, the truck switches to Operational, i.e. the truck runs as normal. Otherwise a question is asked about damage to different parts of the truck. Included in Fleet Management.

Time logoff

Time for automatic logging off. *Del time a -Time to go to Standby. *Del time b -Time to log off. *Dis tiller res (Disable tiller reset) -If the parameter is set to “Yes”, you log on from Standby to Operational by pressing the “I”-button twice. If the parameter is set to “No”, you log on by activating the tiller arm's brake switch.

Smartcard

Smartcard is a unit mounted on the machine housing (servo) or the tiller arm.

Smartcard permits a log on using a card instead of a PIN-code. *Damage rep -Damage log for the Smartcard. Works as the damage log Damage rep.

Disp log on

If the option is enabled the log on time is shown on the display. Otherwise the active time is shown.

Summer time

Automatically sets the clock to summer time.

Keyswitch

If the option is enabled the keyswitch is used instead of the PIN-code when logging on.

Speed red

Speed reduction is connected to a digital input on TMC.

Service-Alarm

Automatic service reminder. *Interval -Time for service interval.

Fixed platf

Activated when a fixed platform is used (only PLP).

TillerUpD

Holding in the button on the tiller arm allows the truck to be driven at crawl speed, without actuating the tiller arm brake switch (only PLL/PSD/PS).

Footswitch

Activates the foot switch on the operator lift (only PP).

Reverse ind

Reversing warning unit which is connected on HVC (only PP).

SERVICE MANUAL

Electrical System / Repair Instructions / ATC Logic

10.33

Raise steer

Accompanying control (only PP).

Dual lift

Double proportional buttons (only PS/PSH)

Straddle

Adjustable support arm (only PSH). Can not be combined with Dual lift.

Belly start

If the parameter is set to “Yes”, the belly switch must be activated in order to log on (used as an “Enter” button). If the parameter is set to “No”, you are immediately logged on once the code has been entered.

*Only shown if the option is activated.

Warning!

When options are stated as being truck specific, under no circumstance may these be activated on any other type of truck than the ones stated. This is on account of the software using the same digital inputs for different functions on different truck models.

ATC Logic The truck control logic is nowadays mainly generated in the ATC software, and not as previously with cabling and the series and parallel connection of switches. For this reason it is no longer possible to measure all the logical conditions by means of a multimeter.

This can now be done with the help of the Monitor menu function for input control. There is no circuit diagram for the software. Instead, a graphic description of the software conditions required for ATC to request procedures has been generated.

The condition does not rule if it is true. Can be compared with a NC contact.

The condition rules if it is true. Can be compared with a NO contact.

Two conditions after each other generate an “and” condition, i.e both conditions must rule for the objective to be achieved. Two parallel conditions generate an “or” condition,

SERVICE MANUAL

10.34

Electrical System / Repair Instructions / ATC Logic

which means that it is sufficient for one of the conditions to rule for the objective to be achieved.

OR

AND

Figure 10.10

Below is an example of how the horn works: Hornbutton 1

ATC sends order to start horn

Hornbutton 2

Figure 10.11

It is therefore sufficient for one of the horn keys to be actuated for it to start.

SERVICE MANUAL

Electrical System / Repair Instructions / ATC Logic

10.35

Direction Selection Throttle command >Deadzone

Safety interlock Tillerswitch

Speed interlock Platform down Platform up

Gates

Forward direction request

Platform down Platform up

Throttle command <Deadzone

Safety interlock Tillerswitch

Speed interlock Platform down Platform up

Grindar

Backward direction request

Platform down Platform up

Figure 10.12

An explanation of the different interlock conditions is available under "Safety Checks" on page 10.27.

SERVICE MANUAL

10.36

Electrical System / Repair Instructions / ATC Logic

Brake System Tiller switch

Speed interlock Engage brake Actual vehicle speed=0

Timer elapsed 500 ms

Throttle command in deadzone

Figure 10.13

An explanation of the different interlock conditions is available under "Safety Checks" on page 10.27. Note that the brake will be automatically engaged after 500 ms on a stationary truck with the speed controller in neutral position.

Lift System Pushbutton raise 1 Pushbutton lower 1

Pushbutton lower 2

Liftstop

Lift interlock Start pumpmotor

Pushbutton raise 2

Pushbutton lower 1 Pushbutton raise 1

Pushbutton raise 2

Lift interlock Opens lowering valve

Pushbutton lower 2

Figure 10.14

An explanation of the different interlock conditions is available under "Safety Checks" on page 10.27.

SERVICE MANUAL

Electrical System / Repair Instructions / Download

10.37

Download Download of Service Data and Logs to a PC 1.

Log off the truck and disconnect the battery connector.

2.

Turn on the PC.

3.

Connect the PC serial COM port to the data connector X3 in the tiller head. Use PC downloding cable ATLET part no 108005.

4.

Reconnect the battery connector.

PC 5.

Start Windows HyperTerminal.

6.

Create a new HyperTerminal connection.

7.

Connect directly to your serial COM port.

8.

Adjust the com parameters as follows:

9.

•

Baud Rate:

9600

•

Data Bits:

8

•

Parity:

None

•

Stop Bits:

1

•

Flow Control:

None

Activate "Capture Text" mode under "Transfer" menu.

Truck 10. Log into "ATLET menu".

11. Select "LOGS/COUNTERS" and "Download".

12. The service information is now transferred to the PC. Disconnect 13. Turn off the HyperTerminal and the PC, log off the truck and disconnect battery plug.

14. Disconnect the PC downloding cable.

Download of "Truck Manager" Statistical Logs to a PC 1.

Log off the truck and disconnect the battery connector.

2.

Turn on the PC.

SERVICE MANUAL

10.38

Electrical System / Repair Instructions / Download

3.

Connect the PC serial COM port to the data connector X30 under the armrest. Use PC downloding cable ATLET part no 108005.

4.

Reconnect the battery connector.

PC 5.

Start Windows HyperTerminal.

6.

Create a new HyperTerminal connection.

7.

Connect directly to your serial COM port.

8.

Adjust the com parameters as follows:

9.

•

Baud Rate:

9600

•

Data Bits:

8

•

Parity:

None

•

Stop Bits:

1

•

Flow Control:

None

Activate "Capture Text" mode under "Transfer" menu.

Truck 10. Log into "LOCAL MENU".

11. Select "FLEET MANAGER" and "Download".

12. The statistical data is now transferred to the PC. Disconnect 13. Turn off the HyperTerminal and the PC, log off the truck and disconnect battery plug.

14. Disconnect the PC downloding cable.

SERVICE MANUAL

Electrical System / Repair Instructions / ATC Connector

10.39

ATC Connector ATC, connector and pin numbering.

XJ13

XJ6

XJ9

XJ5 XJ1 XJ2 XJ3 XJ4 XJ10

XJ14 XJ8 XJ7 XJ12 XJ11

Connector top view:

2 1

XJ8, XJ14

43 21

XJ1, XJ2, XJ3, XJ4, XJ5, XJ9, XJ11, XJ12

6 54 3 21

XJ7

87 65 43 21

XJ10 XJ6

14

1

Figure 10.15 Cortex card

Digital I/Os Digital Inputs ATC There are twelve digital inputs on the ATC card, of which seven are used for the pushbuttons on the tiller arm. The pushbuttons control functions as lift/lower and the horn.

The other five digital inputs are not used in these truck models.

The fact that the inputs are read by ATC can easily be confirmed by selecting Test =>Inputs in the ATLET service menu, and then activating the different functions.

The signal supply of approx. 5V is on pin no 1 in the following connectors: Connector

Function

XJ1.3

Lift

XJ2.3

Lower

XJ3.3

Lift

SERVICE MANUAL

Comment

10.40

Electrical System / Repair Instructions / Digital I/Os

Connector

Function

XJ4.3

Lower

XJ8.1

Horn 1

XJ14.1

Horn 2

Comment

Supply 5V pin no 2.

Digital Inputs TMC There are ten digital inputs in to the TMC, of which seven can be used for these truck models.

Signal supply 24V is taken from pin no X5.2.

Connector

Function

Comment

X5.3

Brake switch

Closes in the upper and lower arm position.

X5.5

Safety gates

Closes in upper position.

X5.6

Platform down switch

Closes when platform is down.

X5.7

Lift stop switch

Breaks at end position.

X5.8

Platform up switch

Closes when platform is up.

X5.9

Fixed platform switch

Closes when standing on the fixed platform (option).

X6.14

Speed reduction switch

Breaks at slow speed and must be set from option menu.

Digital 24V Outputs TMC There are five digital outputs in TMC. Four of these are of the “low side” type, which means that they close to B-. The fifth output is of the “high side” type, which means that it closes to B+. It is this fifth output that closes the lowering valve Y2.

Connector

Function

Comment

X6.1

Energises main contactor K1

24V supply from X6.2.

X6.3

Energises the electric brake Y1 24V supply via brake switch.

X6.4

Energises the lift contactor K2

24V supply via X6.5.

X6.6

Energises the horn H1

24V supply via X6.5.

X6.11

Energises the lowering valve Y2

0V supply via X6.12. NOTE! This output is not shortcircuit-proof.

SERVICE MANUAL

Electrical System / Repair Instructions / Cold Resistance Values

Cold Resistance Values Component

Resistance

Contactor K1

approx. 47 Ohm

Contactor K2

approx. 19 Ohm

Valve coil Y2

approx. 26 Ohm

Brake Y1

approx. 20 Ohm

Fuses Fuses F1

250A

Drive motor

F2

250A

Pump motor

F3

7.5A

Manoeuvring

F4

5A

For extra equipment. Max 120W

F5

25A

Power steering

SERVICE MANUAL

10.41

10.42

Electrical System / Diagnostics and Trouble Shooting / Truck Remote ACcess, TRAC

Diagnostics and Trouble Shooting Truck Remote ACcess, TRAC 00

The purpose of TRAC is to create a remote access to the display and keyboard of the truck, so that an expert can make a remote analysis of the truck and guide local service personnel to trouble shooting.

Prerequisites •

GSM-phone with built in modem and serial cable (local TRAC experts can provide more information on suitable phones).

•

GSM telephone subscription featuring “data call“ and a “data phone“ telephone number.

Utilization After agreement with a TRAC expert to use the TRAC system: •

Prepare and connect according to the connecting procedure below.

•

The TRAC expert may send text messages to you through the display of the truck.

•

When the TRAC session is closed, await a phone call from the expert or call the expert yourself.

•

Disconnect in reverse order (see connecting procedure).

Connecting Procedure 1.

Step to TRAC using the arrow button, and enter the menu with the Enter button.

2.

Choose “init phone“ and return to the TRAC menu with arrow

3.

When the phone rings, choose “answer phone“. Return with arrow

Illustrated instructions are attached to the TRAC cable.

SERVICE MANUAL

. .

Electrical System / Diagnostics and Trouble Shooting / Error Codes

10.43

Error Codes Error Code Indicating ATC: The error codes 1-33 are all memory errors that can occur in conjunction with program errors during unsuccessful reprogramming or during electrostatic discharge.

Table 10.1 Error code indicating E1 ATC invalid NVM access.

Class B

Explanation Attempt to write to invalid E2PROM address.

E2

Not used.

E3

Not used.

E4

Not used.

Control/Procedure Settings lost. No action.

E5 ATC NVM Efficiency log is full.

C

Efficiency log is full (all 100 entries are used) ->first entry will be overwritten.

Settings lost. No action.

E6 ATC NVM Efficiency Log Reset during startup.

C

Efficiency log was corrupt and repaired/cleared during Startup Check.

Settings lost. No action.

E7 ATC NVM C Chronological Impact Log Reset during startup.

Chronological Impact Log was corrupt and repaired/cleared during Startup Check.

Settings lost. No action.

E8 ATC NVM C Chronological Damage Log Reset during startup.

Chronological Damage Log was cor- Settings lost. No action. rupt and repaired/cleared during Startup Check.

E9 ATC NVM Temp Log Reset during startup.

C

Temperature Session Log was corrupt and repaired/cleared during Startup Check.

Settings lost. No action.

C E10 ATC NVM Operator Session Log was corrupt and repaired/ cleared during Startup Check.

Operator Session Log was corrupt and repaired/cleared during Startup Check.

Settings lost. No action.

E11 ATC NVM parameters partially reset during start-up

C

One or more parameters (parameters/accessories/settings) outside the area. This can also happen when the system starts up for the first time.

New settings may be necessary.

E12 ATC NVM local code reset during start-up

C

Local access code outside area (0-9999999). This can also happen when the system starts up for the first time.

New settings may be necessary.

SERVICE MANUAL

10.44

Electrical System / Diagnostics and Trouble Shooting / Error Codes

Table 10.1 Error code indicating

Class

Explanation

Control/Procedure

E13 ATC NVM ATLET code reset during start-up

C

ATLET access code outside area (0-9999999). This can also happen when the system starts up for the first time.

E14 ATC NVM user entry cleared during start-up

C

User ID/code or profile outside area. New settings may be necessary.

E15 ATC NVM error log cleared during start-up

C

Error log corrupt.

No action.

E16 ATC NVM timer (timers) cleared during start-up

C

Timer outside area.

No action.

E17

Not used.

E18

Not used.

E19

Not used.

New settings may be necessary.

E20 ATC NVM ATLET/LOCAL code forced to reset.

C

ATLET/LOCAL code forced to reset in RESET menu.

E21 ATC NVM all users forced to reset.

C

All users forced to reset in the reset menu.

E22 ATC NVM Option Parameters forced to reset.

C

Option Parameters forced to reset in RESET menu.

E23 ATC NVM setting of parameters forced to reset

C

Setting parameters forced to reset in the reset menu.

New settings may be necessary.

E24 ATC NVM calibration parameters forced to reset

C

Calibration parameters forced to reset in the reset menu.

New settings may be necessary.

E25 ATC NVM all logs forced to reset

C

All logs forced to reset in the reset menu.

No action.

E26

New settings may be necessary.

Not used.

E27 ATC NVM error log forced to reset

C

Error logs forced to resest in the ATLET menu.

No action.

E28 ATC NVM temperature log forced to reset

C

Temperature logs forced to resest in the ATLET menu.

No action.

C E29 ATC NVM trip meter time/utilisation forced to reset

Trip meter time/utilisation forced to resest in the ATLET menu.

No action.

SERVICE MANUAL

Electrical System / Diagnostics and Trouble Shooting / Error Codes

10.45

Table 10.1 Error code indicating

Class

Explanation

Control/Procedure

E30 ATC NVM diver log forced to resest in the LOCAL menu

C

driver log forced to resest in the LOCAL menu.

No action.

E31 ATC NVM effective time forced to resest in the LOCAL menu

C

Effective time forced to resest in the LOCAL menu.

No action.

E32 ATC NVM damage log forced to resest in the LOCAL menu

C

Damage log forced to resest in the LOCAL menu.

No action.

E33 ATC NVM collision log forced to resest in the LOCAL menu

C

Collision log forced to resest in the LOCAL menu.

No action.

Not used.

No action.

E34 E35 ATC 1721 Analog Common Pot Low Input Range Fault

B

“ADC PotLowOutput” > ADC COMMON POT LOW SUPERVISION LEVEL.

E36 ATC 1721 Analog Common Pot High Input Range Fault

B

“ADC PotHighOutput” > ADC COMMON POT HIGH SUPERVISION LEVEL.

E37 ATC 1721 Analog Brake Input Range Fault

B

“ADC BrakeOutput” > ADC MAX BRAKE SUPERVISION LEVEL or “ADC BrakeOutput” > ADC MIN BRAKE SUPERVISION LEVEL.

E38 ATC 1721 Analog Raise Input Range Fault

B

“ADC Raise Output” > ADC MAX RAISE SUPERVISION LEVEL or “ADC Raise Output” > ADC MIN RAISE SUPERVISION LEVEL.

E39 ATC 1721 Analog Lower Input Range Fault

B

“ADC Lower Output” > ADC MAX LOWER SUPERVISION LEVEL or “ADC Lower Output” > ADC MIN LOWER SUPERVISION LEVEL.

E40 ATC 1721 Analog A-IN1 Input Range Fault

B

“ADC Aln1 Output” > ADC MAX AIN1 SUPERVISION LEVEL or “ADC Aln1 Output” > ADC MIN AIN1 SUPERVISION LEVEL.

E41 ATC 1721 Analog A-IN2 Input Range Fault

B

“ADC Aln2 Output” > ADC MAX AIN2 SUPERVISION LEVEL or “ADC Aln2 Output” > ADC MIN AIN2 SUPERVISION LEVEL.

E42 ATC 1721 Belly button supervision fault

B

Belly button redundancy check failed.

SERVICE MANUAL

10.46

Electrical System / Diagnostics and Trouble Shooting / Error Codes

Table 10.1 Error code indicating

Class

Explanation

E43 ATC 1721 B Throttle supervision fault

Speed signal / Speed neutral switch check failed.

E44

Not used.

E45

Not used.

Control/Procedure

E46 E47 E48 E49 E50 ATC/TMC low battery

C

Liftlock occurs due to low battery voltage.

Charge the battery.

E51 Com pot low fault

B

Common low supply range fault

1. Replace the lift/lower switch.

2. If the error still occurs replace the ATC.

E52 E53 Hyd pot high fault

Not used B

High supply to hydraulic controls supply range fault

1. Replace the lift/lower switch.

2. If the error still occurs replace the ATC.

E54

Not used

E55

Not used

E56 Lift range fault

B

Lift/lowering signal out of allowed range

E57

Not used.

E58

Not used.

E59

Not used.

SERVICE MANUAL

•

Tiller with on/off buttons: Reset calibration of lift lower and aux 1.

•

Tiller with rocker switch: Check the inductive sensors and the connections.

Electrical System / Diagnostics and Trouble Shooting / Error Codes

10.47

Error Code Indicating TMC:

Table 10.2 Error code indicating

Class

Explanation

Control/Procedure

E100 CAN error

B

CAN communication error TMC on start-up

1. Check that TMC receives voltage supply.

2. Check the CAN communication link between ATC and TMC to make sure there is no fault or short-circuit in the cables.

See wiring diagram.

3. The may be a short-circuit on the ATC or the TMC. Change TMC first and ATC as the other unit.

E101 TMC Watchdog

B

TMC monitoring has triggered.

Try restarting the truck. If this does not help, change TMC.

E102 TMC logic error 1

B

Positive supply voltage to the logic is outside the range.

1. Try restarting 2. Charge the battery if it is getting flat.

3. Check that the thick cables between the motor and TMC are properly tightened and that they have a low ohm factor. Check also the supply cables to TMC, and the cable and voltage supply to contact X5.1.

4. Change TMC. 5. Change drive motor.

E103 TMC logic error 2

B

Error in the part of the logic that handles the return supply of the phase voltage.

1. Try restarting.

2. Charge the battery if it is getting flat.

3. Check that the thick cables between the motor and TMC are properly tightened and that they have a low ohm factor. Check also the supply cables to TMC, and the cable and voltage supply to contact X5.1.

4. Change TMC. 5. Change drive motor.

E104 TMC logic error 3

B

Error in the part of the logic that handles the overlead protection.

1. Try restarting.

If the error recurs, change TMC. 2. Change the motor.

SERVICE MANUAL

10.48

Electrical System / Diagnostics and Trouble Shooting / Error Codes

Table 10.2 Error code indicating

Class

Explanation

Control/Procedure

E105 TMC emergency monitoring has tripped

B

Communication response from TMC has not been received in time.

1. Restart 2. Check the CAN bus cable carefully if the error occurs repeatedly, to make sure there is no play on the connector ring and that the terminal resistance maintains 120 Ohm +/- 5%.

3. Check that the CAN bus is separated from the thick cables. Interferance can give rise to the error.

E106 TMC supply low E107 TMC supply high

B

This test is done on start-up and when stationary (No drive manoeuvre is given).

1. Motor cable fault, connection fault, insulation fault in the motor or to chassis.

2. Change TMC.

E108 TMC contactor closed

A

The main contactor contact tips are closed before voltage has reached the coil.

Check main contactor K1 to make sure the contact tips are not welded, or that it is not short-circuited over the terminals via the cables.

E109 TMC contactor open

A

The logic has low voltage to main contactor K1 but the contactor tips do not close.

1. Break in cables to the coil.

2. Break in coil.

3. The contactor tips do not close, or fail to connect with TMC.

E110 TMC current measuring in standby mode is not equal to zero

B

Check that the current is zero when truck is stationary.

Change TMC.

E111 TMC capacitor charging

B

The capacitor in TMC does not charge up as it should during startup.

1. Check that there is battery voltage to TMC, between B- and contact X5.1.

If not, check battery voltage, supply cables and their connections.

2. Change TMC.

E112 TMC output short-circuited

A

The output to the main contactor coil is short-circuited.

1. Check that there is no short-circuit in main contactor K1, the coil, or that the freewheel diode is not reversed or short-circuited.

Cut the diode and check that there is no short-circuit in the cables to the coil.

2. Change TMC.

SERVICE MANUAL

Electrical System / Diagnostics and Trouble Shooting / Error Codes

10.49

Table 10.2 Error code indicating

Class

Explanation

Control/Procedure

E113 TMC contactor output

B

The output for the main contactor does not function.

1. Change TMC.

E114 TMC coil short-circuited

A

One of the outputs X6.1, X6.3, X6.4 or X6.6 is short circuited.

1. There is a short-circuit in either the main contactor coil K1, the brake coil Y1, lift contactor coil K2, or in the horn.

2. There is a short-circuit in the cabling that connects to the components or in the freewheel diodes, or in the capacitor that suppresses the horn.

3. Internal short-circuit in one of these outputs, change TMC.

E115 TMC generic error

B

TMC self-test does not work.

1. Try restarting a few times.

If this does not rectify the problem, change TMC. NOTE! The error is probably logged together with E123, but should normally never occur.

If E115 or E123 are still be logged, this should be reported to the service function at ATLET AB.

E116 TMC CAN bus

A

Communication command from ATC not received in time.

1. If other CAN errors are logged, rectify these first.

2. There may be an error on ATC, interference on the CAN bus, or play in the CAN bus connector ring.

E117 TMC wrong battery

B

Incorrect battery voltage.

TMC may be incorrectly configured.

Change TMC.

E118 TMC pulse transducer error

B

Error on the signal from the transducer bearing in the drive motor.

Check and measure the transducer in accordance with the trouble shooting chart for "Drive motor" on page 10.53.

E119 E120 TMC EEPROM error

Not used.

C

EEPROM set to default. Error in the range that includes adjustable values.

SERVICE MANUAL

The battery settings have probably been lost. See "Battery Capacity" on page 10.8.

10.50

Electrical System / Diagnostics and Trouble Shooting / Error Codes

Table 10.2 Error code indicating

Class

Explanation

Control/Procedure

E121 TMC controller temperature

Warning C

The internal temperature monitoring has exceeded the 75°C warning level.

The current is limited in relation to the temperature.

TMC stops completely at 100°C.

1. See trouble shooting for "The drive motor looses power and the speed slowly drops." on page 10.55.

2. Change TMC.

E122 TMC motor temperature

Warning C

The drive motor temperature has exceeded the warning level.

1. See trouble shooting for "High temperature in drive motor E122" on page 10.55.

E123 TMC generic

Warning C

Generic warning.

Try restarting a few times.

If the error does not disappear, change TMC. NOTE! The error is probably logged together with E115, but should normally never occur.

If E115 or E123 are still be logged, this should be reported to the service function at ATLET AB.

E124 TMC PEV output

B

The output to lowering valve Y2 connection X6.11 is defective.

First confirm that the valve coil is not short-circuited, that the freewheel diode short-circuits or is reversed, or that there is a short-circuit in the cabling.

NOTE! This output connects to B+ and is not short-circuit-proof. For this reason make sure to check that no external short-circuit exists before changing TMC.

E125 TMC temperature sensor

Warning C

The internal temperature sensor is defective.

Change TMC.

E126 E127 TMC Current sensor error

Not used.

C

Current calibration in progress.

Other Trouble Shooting Main contactor does not close

SERVICE MANUAL

Try restarting a few times.

If this does not help, change TMC.

Electrical System / Diagnostics and Trouble Shooting / Error Codes

10.51

There may be other reasons why the main contactor does not close. For this reason, start trouble shooting by rectifying the last logged primary error code.

Have any related error codes been logged?

No

Change TMC.

No

Check connection X6.2 - K1.1.

No

Measure directly over the main contactor coil. Is there 24V?

Yes

No

Is there 24V to the main contactor plus connection K1.1?

Yes

Is there 24V from TMC connection X6.2?

Yes

Yes

See trouble shooting for respective error codes.

Check if cable connection K1.2 - X6.2 is OK and has low resistance by measuring the resistance to the front edge of X6, when the connector is pulled from TMC, to the front edge of the flat pin. If there is no connection, change or repair the cabling.

Otherwise, change TMC.

Replace contactor.

*The normal cold contactor resistance is approx. 47 ohm.

The truck and ATC have total function loss – the display does not go on Is there 24V between F1 (between the large fuses) and the B- insulation point?

Yes

No

No

Is there 24V between X1.1 and X1.5?

Yes

No

Is there 24V between X1.1 (the contact that connects to the steering arm) and theBinsulation point?

Yes

Is there 24V between insulation bolt X16 and the B- insulation point?

Yes

No

SERVICE MANUAL

Check the battery, battery plug, electrical panel plug and their connections.

Check 7.5A fuse F3, and that there is 24V to one side of the fuse holder. Only measured with the fuse pulled out of the holder.

Check that there is 24V on all the red/white cable connections in connector X21. Either there is a break or poor contact between X16 and X21.1, in toggle X21.1 - X21.2, or in the connection X21.2 - X1.1.

Indicates break or poor connection in the blue minus cable between B- inslation bolt and X1.5.

10.52

Electrical System / Diagnostics and Trouble Shooting / Error Codes

Open the steering arm head. Is there 24V between XJ10.1 and X1J10.5?

Yes

No

Change the steering arm cabling, or repair.

Change ATC.

All minus cables = blue All plus cables in machine housing = red/ white All plus cables in steering arm = red NOTE! There may be a fault on the display or display cable

Fuse The fuse for the drive motor (F1) is defective.

Change the fuse (with correct fuse value) and restart.

The most likely reason is that the mean current exceeds the rated current of the fuse. In conjunction with the change, carefully check the motor cables and the plus and minus cables to TMC to make sure they are correctly connected.

Does the fuse blow just after the main contactor has closed?

No

Yes

Yes

Change TMC. If TMC is defective the most likely error is an exciter error with error codes E106 and E107.

Start the truck again.

Does the fuse blow again after the truck has been running for some time?

Increased friction, increased load, high speed and rapid starting/stopping increase the average current for the controller. The truck may have been driven over its maximum performance.

SERVICE MANUAL

Check that the mechanical torque in the gearbox is not excessive.

If the truck has been run with a heavy load and at a high speed and with many stops and starts, or in some other way has exceeded its limitations, try to reduce the speed, load, acceleration and retardation.

Electrical System / Diagnostics and Trouble Shooting / Error Codes

10.53

Drive motor The drive motor only runs at low speed and with a ticking sound, or alternatively the motor does not start or runs irregularly with a low torque. TMC encoder error E118 is probably logged.

Pull out contact X9 that connects to the drive motor. Is there 12V between pin X6.9 and X6.10 in TMC? Yes

No

No

Measure the voltage between X6.10 and X6.20 at the same time as the motor is run.

An average value of 4-6 volt should be read off when measuring the DC. Ok? Yes

No

Replace the contacts and measure the voltage between X6.10 and X6.19 at the same time as the motor is running. An average value of 4-6 volt should be read off when measuring the DC. Ok? Yes

Is there 12V between pin 1 and 4 in contact X9?

Yes

No

An oscilloscope is required for further trouble shooting to determine whether the pulses from the motor sensor bearing are OK and 90 degrees out of phase. The error can either be in the motor or in TMC. Try the motor if it has low insulation resistance to the chassis. Otherwise start with replacing the TMC.

SERVICE MANUAL

Pull out the contact X6 and check the connections X6.9 - X9.1 and X6.10-X9.4. If the cables are OK, change TMC.

Repair or change the cabling.

Carefully check that the cabling connection between X6.19 and X9.3 is OK and has a low resistance. If not, repair or change the cabling, otherwise change the drive motor.

Carefully check that the cabling connection between X6.20 and X9.2 is OK and has a low resistance. If not, repair or change the cabling, otherwise change the drive motor.

10.54

Electrical System / Diagnostics and Trouble Shooting / Error Codes

Drive function The drive function does not work in one or two directions.

NOTE! If the brakes are applied and correctly adjusted they will hold the truck in spite of full modulation. For this reason, always check if the controller is working. It can be heard as a slight humming sound.

No

Reset the truck

Yes Reset the truck Is there 24V to brake contact X7 when the truck is manoeuvred?

Yes

No

Check that the safety switch has not temporarily jammed. If the error remains it will not be possible to restart the truck, and the question about the safety switch will still be in the display. Check also that the modulation from ATC works from approx.

2.5V in neutral position to close to 5V when driving in the direction of the forks, and close to 0V when driving in the opposite direction to the forks. Recalibrate if necessary.

There may be an error on the brake switch.

Check that the brake switch has not jammed by checking the input for this via the test menu. The switch is normally open when the arm is between its upper and lower position. If there is 24V on TMC contact X5.3 the controller will not modulate and the brake will not be power actuated.

Check that there is 24V on the brake switch contact X4.3 when the arm is in drive position. Check also that there is a connection between X4.3 and X7.1. If not, repair or change the cabling, or alternatively change brake switch S9 if this does not work.

There is either a mechanical or an electrical fault in the brake. The resistance should be approx. 20 Ohm. Test if the brake functions if it is released from the motor. If not, change the brake.

NOTE! The brake switch input is tested during every new start to ensure that it closes to X5.3. If it not, a message is given to release up the arm before driving is permitted.

Also see table and figure 10.7 during which circumstances the truck is in a fault condition and the truck is not allowed to drive.

SERVICE MANUAL

Electrical System / Diagnostics and Trouble Shooting / Error Codes

10.55

High temperature in drive motor E122 If other error codes are logged, rectify these first. The drive motor may have become overheated because it has been run over its performance level for a long period. Check motor and gearbox.

Is the warning also given when the motor is cold?

Yes

No

The truck may have been driven over its maximum performance. There may be a fault on the motor or gearbox. Reduce the drive performance temporarily.

Between X8.1 and X8.2 there is an internal thermo switch connected. If the internal motor temperature is below 125°C this switch is closed, and above 125°C it breaks. Check this switch when the motor is cold and observe that the cable connection X8 must be disconnected from the motor when measuring. If the termo switch seems ok then check that there is no cable break or bad connection in the cabling.

This can be checked with the power on and by measuring that there is 24V to both X8.1 and X8.2 with B- as reference and the motor in a cold condition

Did this solve the problem? If not, change TMC.

For information on temperature log, see "Temperature Log" on page 10.24.

The drive motor looses power and the speed slowly drops.

High temperature in drive controller, error code E121 may be logged. A warning text is normally shown in the display.

TMC starts to module down the motor current linearly at 75°C to stop completely at 100°C. If the error occurs with a cold controller there is probably an error on the TMC internal temperature monitoring. If other error codes are logged, start the trouble shooting by rectifying these first. Otherwise, change the controller.

Check that the fan that cools TMC is working as it should and that the cooling on the TMC are not blocked by dust and dirt. OK? Yes

No

No

Run the truck for an extended period in raised position and without load. Does the temperature in the controller still go over 75°C?

SERVICE MANUAL

Check the fan cabling and that there is 24V to the fan. Otherwise, change the fan and clean up dust and dirt.

The truck may have been driven over its maximum performance. Try to reduce the speed, load, acceleration and retardation.

10.56

Electrical System / Diagnostics and Trouble Shooting / Error Codes

Yes

Try to confirm if there is something that is increasing the torque, such as a worn or jamming gearbox, and if the motor is working normally. OK? Yes

No

Rectify the gearbox or change the motor.

Change TMC

For information on temperature log, see "Temperature Log" on page 10.24.

Lowering of the forks does not work Does ATC read the input(s) in the menu “test inputs”? See, "Monitor menu" on page 10.18 Yes

No

Is there 24V over the valve coil during lowering?

Yes

No

Check that the pushbutton closes at approx. 5V to ATC. Check also that 5V is available, otherwise change ATC.

Test the cable connection between X6.11 and Y2.1 and between X6.12 and Y2.2. If OK, change TMC.

Check that there is no break in the valve coil. A normal resistance value is approx.

19 ohm. If not, change coil.

NOTE! If other pushbuttons for the hydraulic function are actuated at the same time as the lowering button, the lowering is stopped. “Release controls” comes up in the display.

SERVICE MANUAL

Electrical System / Diagnostics and Trouble Shooting / Error Codes

10.57

Lifting of the forks does not work NOTE! All trucks are equipped with end position stop. Before trouble shooting, temporarily set this option to “no”. If this solves the problem the top position switch should be checked in accordance with the trouble shooting chart for this.

Does the lift contactor actuate without the pump running?

Yes

Change the fuse.

No

The contact tips do not seem to conduct.

No

Change the brushes, or adjust.

Check the brushes to the hydraulic unit, and that they are rest against the commutator. OK? Yes

No

Check that 24V goes to the motor terminal.

OK? Yes

Is the fuse F2 intact?

Yes

No

Check that the inputs for lift are read by ATC in the “inputs” menu in the test menu.

If not, check that the pushbuttons work and close when actuated. Check that the pushbuttons receive approx. 5V from ATC. If not, change ATC. Check that there is not a break to pump contactor K2 by checking the cabling, and that there is not a break in the connector coil.

If there is +24 V to the contactor with B- as reference and the contactor still does not pull, change TMC.

Change unit

If the pump runs and the forks still do not lift there may be a fault in the hydraulics, a pump fault, or incorrectly connected hydraulic hoses.

NOTE! • Remember to reset the option for end position switch lift.

•

If the battery is below 20% the lift stop will be actuated. Charge the battery.

•

If other pushbuttons for the hydraulic function are actuated at the same time as the lifting button, the lifting is stopped. “Release controls” comes up in the display.

•

Normal pump motor current values are approximately 38A without load, 105A with 2500kg and 125A at end stop. The end stop value can be checked if the option “lift limit“ is temporarily set to no. See options menu under Menu Tree Atlet Menu.

SERVICE MANUAL

10.58

Electrical System / Diagnostics and Trouble Shooting / Error Codes

The top position switch for lifting does not function The top position switch for lifting must normally be closed to enable lifting. The switch function can be checked in "Monitor menu" on page 10.18 Pull apart contact X15 and measure the resistance of the switch between pin 1 and 2 when the forks are completely lowered.

OK? Yes

No

Check that there is 24V to the switch and that TMC receives 24V on contact X5.7.

OK? Yes

No

Remove the option for top position switch in the options menu, or alternatively change TMC.

SERVICE MANUAL

Check that the switch is not in mechanically actuated position. If OK, change switch.

Check the cabling and that TMC supplies 24 V from contact X5.2. If not, change TMC.

Electrical System / Appendix 1, Summary menu tree / Error Codes

10.59

Appendix 1, Summary menu tree In the following section, Appendix 1, menu trees ( Software 2.23) can be found for the menus listed below:

•

Menu tree, Local menu

•

Menu tree, Atlet menu

•

Menu tree, Monitor menu

•

Menu tree, Reset menu

•

Menu tree, Language

•

Menu tree, TRAC

SERVICE MANUAL

10.60

Electrical System / Appendix 1, Summary menu tree / Error Codes

SERVICE MANUAL

1

Local Menu Tree Level 1 LOCAL MENU: < Exit

LOCAL MENU: < Set access

Level 2

Level 3

Level 4

Level 5

Remarks:

>

SET ACCESS: ENT / v -> Operator

OPERATOR: ^ ENT -> New/Change

The level 3 displays are always followed in sequence.

The no of question marks corresponds to the chosen id length (ATLET menu).

Operator ID: ENT ->

?

Operator categ:x ?

Old code: ????

New code: ????

Verify new code: ????

Ok! Press ENT Not successful!

this screens will only be displayed if the user ID exists and user code length > 0 The no of question marks corresponds to the chosen code length (ATLET menu). this screens will only be displayed if the user code length > 0 The no of question marks corresponds to the chosen code length (ATLET menu). this screens will only be displayed if the user code length > 0 The no of question marks corresponds to the chosen code length (ATLET menu).

invalid old code / verifyed code wrong / category out of range (1..4) / all 100 user ID's used / no access to E2PROM

Press ENT OPERATOR: Format

ENT -> 0

CAUTION! Reduced length may lead. v

^

.to lost entries 0:escape 1:go on 1 Id length:

Code length:

SET ACCESS: Delete oper

ENT ->

x ^

ENT ->

Id length: x New value: ?

Id length: x New value saved!

Input rejected!

Press ENT Code length: x New value: ?

Code length: x New value saved!

Input rejected!

Press ENT The level 3 displays are always followed in sequence.

Operator ID: ^ ENT ->

x v

?

Delete op x?

0:No 1:Yes (No) Ok! Press ENT Not successful!

Press ENT

invalid ID / 0:(No) pressed or input aborted/ no access to E2PROM

2

Local Menu Tree Level 1

Level 2

SET ACCESS: Local

Level 3

^ ENT ->

Level 4

Level 5

Remarks:

The level 3 displays are always followed in sequence.

Old code: ???????

New code: ???????

Verify new code: ???????

Ok! Press ENT Not successful!

Press ENT

invalid old code / verifyed code wrong / no access to E2PROM

This menu entry resets the Impact Sensor actions. To be used by warehouse manegement to acknowledge impact.

LOCAL MENU: FLEET MANAGER: <Fleet manager ENT / v -> Unlock ^v FLEET MANAGER: READ LOGS: Read logs ^ ENT -> Operator log READ LOGS: Efficiency

List of the 30 most recent operator sessions.

^

ENT ->

<o>: [date] [time] - [time]

^

ENT ->

EFFICIENCY: Worst

^v

ENT ->

<o>: xx(mn)% List sorted from worst to best operator (Act). xx = active time / logged on time * 100; Curr:iii(mn)A iii = mean main active current draw; mn = corresponding mean value for all operators;

EFFICIENCY: Best

^v

ENT ->

<o>: xx(mn)% List sorted from best to worst operator (Act). xx = active time / logged on time * 100; Curr:iii(mn)A iii = mean main active current draw; mn = corresponding mean value for all operators;

?

ENT ->

<o>: xx(mn)% Any operator's efficiency. <o> = operator id (1 - 100) T:xx(mn)P:xx(mn) T = traction; P = pump; mn = corresponding mean value for all operators;

Operator id:

READ LOGS: Damage log

<o>:

DAMAGE LOG: ^

ENT ->

Worst

^v

ENT ->

DAMAGE LOG:

<o>: ^v

ENT ->

DAMAGE LOG: Chronological ^ v

ENT ->

Best

<o>:

<o>:

xxx(mn) <o> = operator who used the truck immediately before damage was reported. xxx = number of reported damages. List sorted from greatest to smallest no of reported xxx(mn) damages. xxx(mn) <o> = operator who used the truck immediately before damage was reported. xxx = number of reported damages. List sorted from smallest to greatest no of reported xxx(mn) damages.

30:[date] [time] List sorted in chronological order. <o>: <dc> <o> = operator who used the truck immediately before damage was reported. v <dc> = damage code (max two characters long). v v 01:[date] [time] <o>: <dc>

3

Local Menu Tree Level 1

Level 2

Level 3

Level 4

Level 5

READ LOGS: Impact log

IMPACT LOG: Worst

^v

ENT ->

not implemented yet ! <o>: ^xx(mn) Top = peak impact value; mn = mean impact value for all operators; IOM:xxx Mn:xxx% IOM = number of impacts over mean (mn); Mn = operator's mean value.

IMPACT LOG: Best

^v

ENT ->

<o>: ^xx(mn) Top = peak impact value; mn = mean impact value for all operators; IOM:xxx Mn:xxx% IOM = number of impacts over mean (mn); Mn = operator's mean value.

IMPACT LOG: Chronological ^ v

ENT ->

^

ENT ->

Remarks:

30:[date] [time] List sorted in chronological order. <o>: <il> <o> = operator who used the truck immediately before damage was reported. v <il> = impact level (max two characters long). v v 01:[date] [time] <o>: <il>

FLEET MANAGER: Download ^ ENT -> Send fleet manager data to serial port.

FLEET MANAGER: RESET LOG: Reset ^ ENT -> Operator log

^

RESET LOG: Effic/Dmg/Imp

LOCAL MENU: < Settings

SETTINGS: > ENT / v -> Time & Date

SETTINGS: LCD contrast

ENT ->

Reset optr log?

0:No 1:Yes (No)

ENT ->

Resetthis log?

0:No 1:Yes (No)

TIME & DATE: ^ ENT / v -> Set time

^

ENT ->

New time:

TIME & DATE: Set date

^

ENT ->

New:

TIME & DATE: Date format

^

ENT ->

LCD contrast: ^ ENT / v ->

x ENT ->

11:39 hh:mm hh:mm Ok! Press ENT Input rejected!

Press ENT dd.mm.yyyy yy-mm-dd 2001-09-18 Ok! Press ENT Input rejected!

Press ENT Select format: 2001-09-18 ^v 18-Sep-01 ^v 18.09.2001 ^v 09.18.2001 ^v LCD contrast: x New value: ?

LCD contrast: y New value saved!

Input rejected!

Press ENT

x = 0..9

4

Local Menu Tree Level 1

Level 2

SETTINGS: Key sound

Level 3

Key sound:

Level 4

xxx

^ ENT / v ->

LOCAL MENU: CARD READER: Smartcard:xxx < Card reader ENT / v -> Enable/disable ENT / v -> ^v

ENT ->

ENT ->

Key sound: xxx 0:no 1:yes Key sound: yyy New value saved!

Input rejected!

Press ENT

smartcard:xxx 0:no 1:yes smartcard:yyy New value saved!

Input rejected!

Press ENT

Level 5

Remarks:

1

TRAC TRAC MENU: < Exit TRAC MENU: < Initphone

> Initphone ENT / v ->

TRAC MENU: < Answer call

>

Answer call >

ENT / v ->

1

ATLET Menu tree Level 1 ATLET MENU: < Exit

Level 2 >

ATLET MENU: < Options

>

Level 3

Lift limit: ENT / v ->

Restart:

xxx ^v

ENT ->

xxx ^v

ENT ->

Safety syst:xxx ^v

ENT ->

Effici log:xxx ^v

ENT ->

Lift limit: xxx 0:no 1:yes Lift limit: yyy New value saved!

Input rejected!

Press ENT Restart: xxx 0:no 1:yes Restart: yyy New value saved!

Input rejected!

Press ENT Safety syst:xxx 0:no 1:yes Safety syst:yyy New value saved!

Input rejected!

Press ENT Effici log:xxx 0:no 1:yes Effici log:yyy New value saved!

Input rejected!

Press ENT

Level 4

Level 5

Level 6

Remarks:

xxx = currently used value.

New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

2

ATLET Menu tree Level 1

Level 2 Impact sens:xxx ^v

ENT ->

Log level: xxx ^v

ENT ->

Horn level :xxx ^v

ENT ->

Warning lev :xxx ^v

ENT ->

Stop level:xxx ^v

ENT ->

Supervis lev :xxx ^v

ENT ->

Damage rep:xxx ^v

ENT ->

Level 3 Impact sens:xxx 0:no 1:yes Imp sensor:yyy New value saved!

Input rejected!

Press ENT Log level: xxx New value: ?

Log level: yyy New value saved!

Input rejected!

Press ENT Horn level :xxx New value: ?

Horn level :yyy New value saved!

Input rejected!

Press ENT Warning lev :xxx New value: ?

Warning lev :yyy New value saved!

Input rejected!

Press ENT Stop level:xxx New value: ?

Stop level:yyy New value saved!

Input rejected!

Press ENT Supervis lev :xxx New value: ?

Supervis lev :yyy New value saved!

Input rejected!

Press ENT

Damage rep:xxx 0:no 1:yes Damage rep:yyy New value saved!

Input rejected!

Press ENT

Level 4

Appears only if Imp sensor is 'yes' above!

Level 5

Level 6

Remarks:

3

ATLET Menu tree Level 1

Level 2 Time logoff:xxx ^v

ENT ->

Del time a: xxx ^v

ENT ->

Del time b: xxx ^v

ENT ->

Dis tiller res:xxx ^v

ENT ->

Smartcard:xxx ^v

ENT ->

Damage rep:xxx ^v

ENT ->

Disp log on:xxx ^v

ENT ->

Summer time:xxx ^v

ENT ->

Keyswitch

:xxx ^v

ENT ->

Level 3 Time logoff:xxx 0:no 1:yes Time logoff:yyy New value saved!

Input rejected!

Press ENT

Level 4

Appears only if Time logoff is 'yes' above!

Del time a:xxs New value: ?

Delay time a:yys New value saved!

Input rejected!

Press ENT Del time b:xxmin New value: ?

Delay time b:yymin New value saved!

Input rejected!

Press ENT Dis tiller res:xxx 0:no 1:yes Dis tiller res:yyy New value saved!

Input rejected!

Press ENT smartcard:xxx 0:no 1:yes smartcard:yyy New value saved!

Input rejected!

Press ENT Damage rep:xxx 0:no 1:yes Damage rep:yyy New value saved!

Input rejected!

Press ENT

Disp log on:xxx 0:no 1:yes Disp log on:yyy New value saved!

Input rejected!

Press ENT Summer time:xxx 0:no 1:yes Summer time:yyy New value saved!

Input rejected!

Press ENT Keysw pwr of:xxx 0:no 1:yes Keysw pwr of:yyy New value saved!

Input rejected!

Press ENT

Appears only if Time logoff is 'yes' above!

Level 5

Level 6

Remarks:

4

ATLET Menu tree Level 1

Level 2

Level 3

Speed red:xxx ^v

Cutback3:

ENT ->

xxxx% ^v

ENT ->

Service alrm:xxx ^v

ENT ->

Interval:

xxxxh ^v

Fixed platf.

TillerUpD

Footswitch

Reverse ind

:xxx ^v

ENT ->

ENT ->

:xxx ^v

ENT ->

:xxx ^v

ENT ->

:xxx ^v

ENT ->

Speed red:xxx 0:no 1:yes Speed red:yyy New value saved!

Input rejected!

Press ENT

Level 4

Appears only if Speed red is 'yes' above!

Cutback3: xxxx% New value: ?

Cutback3: yyyy% New value saved!

Input rejected!

Press ENT

Service alrm:xxx 0:no 1:yes Service alrm:yyy New value saved!

Input rejected!

Press ENT Interval: xxxxh New value: ?

Interval: yyyyh New value saved!

Input rejected!

Press ENT

Fixed platf.:xxx 0:no 1:yes Fixed Platf:yyy New value saved!

Input rejected!

Press ENT TillerUpD :xxx 0:no 1:yes TillerUpD :yyy New value saved!

Input rejected!

Press ENT Footswitch :xxx 0:no 1:yes Footswitch :yyy New value saved!

Input rejected!

Press ENT Reverse ind :xxx 0:no 1:yes Reverse ind :yyy New value saved!

Input rejected!

Press ENT

Appears only if Service alrm is 'yes' above!

Level 5

Level 6

Remarks:

5

ATLET Menu tree Level 1

Level 2

Level 3

Raise steer

ENT ->

:xxx ^v

ENT ->

Dual lift

:xxx ^v

Straddle

:xxx

Belly start

ATLET MENU: < Settings

>

ENT / v ->

SETTINGS: Performance

^v

ENT ->

:xxx ^v

ENT ->

^v

ENT ->

Level 4

Level 5

Level 6

Remarks:

Raise steer :xxx 0:no 1:yes Raise steer :yyy New value saved!

Input rejected!

Press ENT Dual lift :xxx 0:no 1:yes Dual lift :yyy New value saved!

Input rejected!

Press ENT Straddle :xxx 0:no 1:yes Straddle :yyy New value saved!

Input rejected!

Press ENT Belly start :xxx 0:no 1:yes Belly start :yyy New value saved!

Input rejected!

Press ENT

PERFORMANCE: Op category 1 ^ v

Fwd speed: ENT ->

Rev

xxx% ^v

speed :xxx% ^v

Tract accel:xxx% ^v Tract cutb1:xxx% ^v Tract cutb2:xxx% ^v Tract curr :xxx% ^v Rdc brake :xxx% ^v Neut brake :xxx% ^v Rev brake :xxx% ^v Brake pedal:xxx% ^v Steer hi spd::xxx% ^v

ENT ->

ENT ->

Fwd speed: xxx% New value: ?

Fwd speed: yyy% New value saved!

Input rejected!

Press ENT Rev speed :xxx% New value: ?

Rev speed: yyy% New value saved!

Input rejected!

Press ENT

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

xxx = currently used value.

New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

6

ATLET Menu tree Level 1

Level 2

SETTINGS: Traction

Level 3

^v

ENT ->

Level 4

Level 5

PERFORMANCE: Op category 2 ^ v

ENT ->

Acc to above

PERFORMANCE: Op category 3 ^ v

ENT ->

Acc to above

PERFORMANCE: Op category 4 ^ v

ENT ->

TRACTION: Throttle map

ENT ->

Breakp hi:

Deadzone:

TRACTION: Brake map

Breakp lo: ^v

ENT ->

Breakp hi:

Deadzone:

TRACTION: Motor type

Motor: ^v

ENT ->

Remarks:

Acc to above Breakp lo:

^v

Level 6

xxx% ^v

ENT ->

xxx% ^v

ENT ->

xxx% ^v

ENT ->

xxx% ^v

ENT ->

xxx% ^v

ENT ->

xxx% ^v

ENT ->

NN ENT ->

Breakp lo: xxx% New value: ?

Breakp lo: yyy% New value saved!

Input rejected!

Press ENT

Defines the ouput signal level at 30% of the input signal 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Breakp hi: xxx% New value: ?

Breakp hi: yyy% New value saved!

Input rejected!

Press ENT

Defines the ouput signal level at 70% of the input signal 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Deadzone: xxx% New value: ?

Deadzone: xxx% New value saved!

Input rejected!

Press ENT

'xxx' = 'on' or 'off' (currently used)

Breakp lo: xxx% New value: ?

Breakp lo: xxx% New value saved!

Input rejected!

Press ENT

Defines the ouput signal level at 30% of the input signal 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Breakp hi: xxx% New value: ?

Breakp hi: xxx% New value saved!

Input rejected!

Press ENT

Defines the ouput signal level at 70% of the input signal 'xxx' = 'on' or 'off' (currently used) New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Deadzone: xxx% New value: ?

Deadzone: xxx% New value saved!

Input rejected!

Press ENT

'xxx' = 'on' or 'off' (currently used)

Motor: NN 0:Kordel 1:Sauer Motor: NN New value saved!

Input rejected!

Press ENT

New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

7

ATLET Menu tree Level 1

Level 2

SETTINGS: Brake

Level 3

^v

Level 4

Level 5

Level 6

Remarks:

ENT ->

SETTINGS: Pump

^v

ENT ->

Cont Delay: xr

SETTINGS: Hydraulics

^v

ENT ->

ENT ->

HYDRAULICS: HVC Setup

Cont Delay: xr New value: ?

Cont Delay: xr New value saved!

Input rejected!

Press ENT

HVC 1: ^v

ENT ->

xxx ^v

HVC 1 PWM:xxxxHz ^v

xxx ^v HVC 2 PWM:xxxxHz ^v HVC 3: xxx ^v HVC 3 PWM:xxxxHz ^v HVC 4: xxx ^v HVC 4 PWM:xxxxHz ^v

ENT ->

ENT ->

HVC 1: xxx 0:off 1:on HVC 1: yyy New value saved!

Input rejected!

Press ENT

'xxx' = 'on' or 'off' (currently used)

HVC 1 PWM:xxxHz New value: ?

HVC 1 PWM:yyyHz New value saved!

Input rejected!

Press ENT

'xxx' = currently used value

HVC 2:

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

New value 'yyy' replaces the old 'xxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

8

ATLET Menu tree Level 1

Level 2

Level 3 HYDRAULICS: Lift

^v

ENT ->

Level 4 Raise ctrl:xxxxx ^v

Speed ctrl:xxxxx ^v

Raise min:

xxx% ^v

xxx% ^v Lower min: xxx% ^v Lower max: xxx% ^v Breakp: xxx% ^v Deadzone: xxx% ^v

ENT ->

ENT ->

ENT ->

Level 5 Raise ctrl:xxxxx 0:OnOff 1:Speed Raise ctrl:yyyyy New value saved!

Input rejected!

Press ENT Speed ctrl:xxxxx 0:Valve 1:Motor Speed ctrl:yyyyy New value saved!

Input rejected!

Press ENT

Level 6

Remarks: 'xxxxx' = currently used value New value 'yyyyy' replaces the old 'xxxxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Appears only if speed control is selected above!

Refers to [ valve PWM ] or [ pump motor speed ] depending on choice above. Note that the min/max parameters only are used if speed control are selected.

Raise min: xxx New value: ?

Raise min: yyy New value saved!

Input rejected!

Press ENT

Raise max:

HYDRAULICS: Channel 2

Ch2 ctrl: ^v

ENT ->

xxxxx ^v

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

Defines the ouput signal level at 50% of the input signal

ENT -> ENT -> <- OnOff

Speed ctrl:xxxxx ^v

Ch2 pos min:xxx% ^v

Ch2 pos max:xxx% ^v Ch2 neg min:xxx% ^v Ch2 neg max:xxx% ^v Breakp: xxx% ^v Deadzone: xxx% ^v

acc to above!

Ch2 ctrl: xxxxx 0:OnOff 1:Speed Ch2 ctrl: yyyyy New value saved!

Input rejected!

Press ENT Speed ctrl:xxxxx 0:Valve 1:Motor Speed ctrl:yyyyy New value saved!

Input rejected!

Press ENT

ENT ->

Pos min: xxx New value: ?

Pos min: yyy New value saved!

Input rejected!

Press ENT

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

ENT ->

acc to above!

'xxxxx' = currently used value New value 'yyyyy' replaces the old 'xxxxx'.

Screen stays on for 1 s.

Displayed if value is out of range.

Appears only if speed control is selected above!

Refers to [ valve PWM ] or [ pump motor speed ] depending on choice above.

Defines the ouput signal level at 50% of the input signal

9

ATLET Menu tree Level 1

Level 2

Level 3

Level 4

HYDRAULICS: Channel 3

^v

HYDRAULICS: Channel 4

^v

HYDRAULICS: ramps ^v

ENT ->

Acc to above

ENT ->

Acc to above

ENT ->

Open ramp:

Level 5

^v

Closing ramp: ^v

SETTINGS: Steering

EPS: ^v

xxx ^v

ENT ->

Steer ctrl:xxxxx ^v

ENT ->

ENT ->

Limit rough: ^v

ENT ->

Limit fine CW: ^v

Limit fine CCW: ^v

ENT ->

ENT ->

xr ENT ->

xr ENT ->

Open ramp: New value: ?

Open ramp: New value saved!

Input rejected!

Press ENT Closing ramp: New value: ?

Closing ramp: New value saved!

Input rejected!

Press ENT

EPS: xxx 0:off 1:on EPS: yyy New value saved!

Input rejected!

Press ENT Steer ctrl:xxxxx 1:Speed 2:Posit Speed ctrl:yyyyy New value saved!

Input rejected!

Press ENT Limit rough: New value: ?

Limit rough: New value saved!

Input rejected!

Press ENT

xx xx

Limit fine CW: New value: ?

Limit fine CW: New value saved!

Input rejected!

Press ENT Limit fine CCW: New value: ?

Limit fine CCW: New value saved!

Input rejected!

Press ENT

xx xx

xx xx

Level 6

xr xr

xr xr

Remarks:

10

ATLET Menu tree Level 1

Level 2

SETTINGS: Battery

SETTINGS: Trucktype

ATLET MENU: < Tests

>

ENT / v ->

TESTS: Inputs

Level 3

^v

^v

^v

ENT ->

Level 4

BATTERY: Calibrate

^v

ENT ->

BATTERY: Stepdown hi

^v

ENT ->

BATTERY: Stepdown lo

^v

ENT ->

Level 5

Level 6

Remarks:

Measured: xxx New value: ?

Measured: yyy New value saved!

Input rejected!

Press ENT Stepdown hi: x New value: ?

Stepdown hi: y New value saved!

Input rejected!

Press ENT Stepdown lo: x New value: ?

Stepdown lo: y New value saved!

Input rejected!

Press ENT XX = trucktype

ENT ->

TRUCKTYOE XX

ENT ->

TEST INPUTS: Overview

^v

ENT ->

111222333444555A 66677BCDEFGHIJK

TEST INPUTS: Accelerator

^v

ENT ->

Signal check: x.x V Out:syyy%

Strings of the same digit are bar graphs for analog/steering enc inputs. The digit identifies the input, and the number of digits represents the input signal level.

E.g "1" means: 10%<spd cmd<50%, "11" means: 50%<spd cmd<90%, "111" means: spd cmd>90%. s' = sign Single letters means digital input activated.

TEST INPUTS: Brake

^v

ENT ->

Signal check: x.x V Out:syyy%

s' = sign

s' = sign

TEST INPUTS: Lift

^v

ENT ->

Signal check: x.x V Out:syyy%

TEST INPUTS: Aux AI 1

^v

ENT ->

Signal check: x.x V Out:syyy%

s' = sign

TEST INPUTS: Aux AI 2

^v

ENT ->

Signal check: x.x V Out:syyy%

s' = sign

s' = sign

TEST INPUTS: Aux AI 3

^v

ENT ->

Signal check: x.x V Out:syyy%

TEST INPUTS: Steering

^v

ENT ->

Steering rpm: syyy

11

ATLET Menu tree Level 1

Level 2 TESTS: Outputs

^v

ENT ->

Level 3 TEST OUTPUT: LED 1

^v

ENT ->

TEST OUTPUT: LED 2

^v

ENT ->

TEST OUTPUT: OUT 4

^v

ENT ->

TEST OUTPUT: HEATER

TESTS: Versions

^v

ENT ->

Level 4

^v

Level 5

Level 6

Remarks: If "ENT" is pressed, the currently displayed output will be engaged as long as the key is kept pressed.

ENT ->

TEST OUTPUT: ANALOG OUT

ENT ->

READ VERSION: Traction ^v

ENT ->

HW: SW:

READ VERSION: HVC ^v

ENT ->

HW: SW:

READ VERSION: Power steering^ v

ENT ->

HW: SW:

READ VERSION: ATC ^v

ENT ->

HW: MM.mm VCL SW: MM.mm

^v

OS date: yy-mm-dd OS ver: MM.mm ^v

TESTS: TM encoder

0:no ^v

1:yes:

ENT -> enc disabled Press ENT

ATLET MENU: < Calibrate

>

ENT / v ->

CALIBRATE: All

^v

ENT ->

CALIBRATE: Accelerator

^v

ENT ->

<- ENT

CALIBRATE: Brake

^v

ENT ->

<- ENT

Release throttle and press ENT Go to end points and press ENT OK!: Press ENT Not successful!

Press ENT Signal check: x.x V Out:syyy%

Covers both butterfly and pedal type throttle The level 3 displays are always followed in sequence.

Release brake and press ENT Order full brake and press ENT OK!: Press ENT Not successful!

Press ENT Signal check: x.x V Out:syyy%

The level 3 displays are always followed in sequence.

s = sign (+ raise, - lower)

12

ATLET Menu tree Level 1

Level 2 CALIBRATE: Lift

^v

ENT ->

<- ENT

CALIBRATE: Channel 2

^v

ENT ->

<- ENT

CALIBRATE: Channel 3

^v

ENT ->

CALIBRATE: Channel 4

^v

ENT ->

CALIBRATE: Steering

CALIBRATE: Update angle

^v

^v

ENT ->

ENT ->

Level 3 Release lift and press ENT Order full raise and press ENT Order full lower and press ENT OK!: Press ENT Not successful!

Press ENT Signal check: x.x V Out:syyy% Release ch2 and press ENT Order full +dir and press ENT Order full -dir and press ENT OK!: Press ENT Not successful!

Press ENT Signal check: x.x V Out:syyy%

According to "Channel 2"

According to "Channel 2" Center steering and press ENT Calibration done press ENT Calicrate failed Press ENT

Update angle

Level 4

Level 5

Level 6

Remarks: Covers both combined and separate raise/lower controls.

The level 3 displays are always followed in sequence.

s = sign (+ raise, - lower)

13

ATLET Menu tree Level 1

Level 2

ENT / v ->

LOGS/COUNTERS: Error log ^v

ENT ->

ATLET MENU: <Logs/counters > Appears only if the error is a VCL or OS ERROR instead of the 2 screens above! No secondary log is possible.

Level 3

Level 4

30: Exxx < [date] [time] ENT -> v^ [error text line 1] [error text line 2] v^ #yyy occurred: [date] [time] v^ next primary error…

+01: Exxx Offset: v^ [error text [error text v^ +02: Exxx Offset: v^ [error text [error text v^ +03: Exxx Offset: v^ [error text [error text v^ +04: Exxx Offset: v^ [error text [error text v^

VCL (or OS) ERROR Module id: mmm v^ Error id: eee Line: LLL

LOGS/COUNTERS: Temp log ^v

ENT ->

LOGS/COUNTERS: Hour meters ^ v

ENT ->

Level 5

zzz ms line 1] line 2]

Level 6

Remarks:

Latest error is shown first.

The [i] key can be used to jump directly to the next error (primary and secondary error log) xxx is the error code yyy is the number of errors occured "+" idicates that there is a secondary error

zzz ms line 1] line 2]

zzz ms line 1] line 2]

zzz ms line 1] line 2] Temperatures for traction motor, traction controller, pump motor, pump controller, hydr oil, power steering motor, power steering controller, all in five intervals. Intervals differs depending on the objects working temperature range.

Tract motor temp - 60C:xxxx.xh v v v Tract motor temp 121 :xxxx.xh HOUR METER: Total

^v

ENT ->

HOUR METER: Trip

^v

ENT ->

HOUR METER: Read external ^ v

ENT ->

TOTAL Active: xxxxx.yyyh TOTAL Logged on: xxxxx.yyyh TOTAL Traction: xxxxx.yyyh TOTAL Pump: xxxxx.yyyh

xxxxx -> hours yyy -> 1/1000 hours

TRIP Active: xxxxx.yyyh TRIP Logged on: xxxxx.yyyh TRIP Traction: xxxxx.yyyh TRIP Pump: xxxxx.yyyh

xxxxx -> hours yyy -> 1/1000 hours

READ Traction: xxxxx h READ Pump: xxxxx h READ Pwr Steer: xxxxx h

14

ATLET Menu tree Level 1

Level 2

Level 3

Level 4

ENT ->

Tract: iii A xx% Pump: iii A xx%

LOGS/COUNTERS: Reset ^v

ENT ->

RESET: Error log

^v

ENT ->

RESET: Temp log

^v

ENT ->

RESET: Trip meters/Util^ v

ENT ->

RESET: Service alarm ^ v

ENT ->

SET HOURS: Logged on ^ v

ENT ->

SET HOURS: Active ^ v

ENT ->

SET HOURS: Traction ^ v

ENT ->

SET HOURS: Pump ^ v

ENT ->

ENT ->

Level 6

Remarks: "iii" is the calculated "mean main active current", "xx" is calculated as: [active time] / [calendar time since last reset].

LOGS/COUNTERS: Utilisation ^v

LOGS/COUNTERS: Set hour mtrs ^v

Level 5

Reset error log?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT Reset temp log?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT Reset trip/util?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT Reset service?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT Logged on

Active:

xxxh ENT ->

xxxhActive: xxx ENT -> New value: ?

Active: yyy New value saved!

Input rejected!

Press ENT

Traction: ENT ->

Pump:

Logged on: xxx New value: ?

Logged on: yyy New value saved!

Input rejected!

Press ENT

xxTraction: xxx New value: ?

Traction: yyy New value saved!

Input rejected!

Press ENT

xxxh ENT ->

Pump: xxx New value: ?

Pump: yyy New value saved!

Input rejected!

Press ENT

Hour meters can only be set to a higher value than before.

15

ATLET Menu tree Level 1

Level 2

ENT / v -> ATLET MENU: < Set access

Level 3

Level 4

Level 5

Level 6

Remarks:

LOGS/COUNTERS: Download ^v

ENT ->

Send all above logs to serial port truck serial no, versions and settings (not fleet manager statistics)

SET ACCESS: Operator

ENT ->

OPERATOR: New/Change

^v

ENT ->

>

OPERATOR: Format

The level 3 displays are always followed in sequence.

The no of question marks corresponds to the chosen id length (ATLET menu).

Operator ID: ^v

^v

ENT -> 0

?

Operator categ:x ?

Old code: ????

New code: ????

Verify new code: ????

Ok! Press ENT Not successful!

Press ENT

this screens will only be displayed if the user ID exists and user code length > 0 The no of question marks corresponds to the chosen code length (ATLET menu). this screens will only be displayed if the user code length > 0 The no of question marks corresponds to the chosen code length (ATLET menu). this screens will only be displayed if the user code length > 0 The no of question marks corresponds to the chosen code length (ATLET menu).

invalid old code / verifyed code wrong / category out of range (1..4) / all 100 user ID's used / no access to E2PROM

CAUTION! Reduced length may lead. v

^

.to lost entries 0:escape 1:go on 1 Id length:

Code length:

SET ACCESS: Local

x v

ENT ->

x ^

ENT ->

Id length: x New value: ?

Id length: x New value saved!

Input rejected!

Press ENT Code length: x New value: ?

Code length: x New value saved!

Input rejected!

Press ENT

Old code: ^v

ENT ->

???????

New code: ???????

Verify new code: ???????

Ok! Press ENT Not successful!

Press ENT

SET ACCESS: Atlet

invalid old code / verifyed code wrong / no access to E2PROM

Old code: ^v

ENT ->

???????

New code: ???????

Verify new code: ???????

Ok! Press ENT Not successful!

Press ENT

ENT -> ATLET MENU: < Total reset

>

Go to Reset menu

invalid old code / verifyed code wrong / no access to E2PROM

16

ATLET Menu tree Level 1

Level 2

Level 3

Selection is done 'semiautomatically' during CALIBRATION between: 1. Combined raise/lower control (e g joystick) 2. Individual raise and lower controls (e g pushbuttons in tiller head)

Level 4

Level 5

Level 6

Every unique VCL sw variant includes rules for: 1. which inputs are allowed to be used to each channel. Final decision of which of these allowed inputs will be used is made by 'auto-sense' feature during calibration.

Selection is done 'semiautomatically' during CALIBRATION between: 1. Combined pos/neg direction control (e g joystick) INPUTS pos Atlet menu/Calibrate 2. Individual and neg direction controls (e g pushbuttons in tiller head)

Hydraulic Control Channels

2. which outputs will be used: a) if onoff control is selected b) if valve VCL appl PWM code is selected c) if motor speed control is selected.

3. which interlocks should exist between the different channels.

Lift channel Selection is done 'semiautomatically' during CALIBRATION between: 1. Combined pos/neg direction control (e g joystick) 2. Individual pos and neg direction controls (e g pushbuttons in tiller head)

Channel 2 Selection is done 'semiautomatically' during CALIBRATION between: 1. Combined pos/neg direction control (e g joystick) 2. Individual pos and neg direction controls (e g pushbuttons in tiller head)

Selection decided in SETTINGS between: OUTPUT isAtlet menu/Settings/Hydraulics 1. OnOff control.

2. Speed control.

2.1 Valve PWM control.

2.2 Pump motor speed control.

Selection is decided in SETTINGS between: 1. OnOff control.

2. Speed control.

2.1 Valve PWM control.

2.2 Pump motor speed control.

Channel 3

Selection is decided in SETTINGS between: 1. OnOff control.

2. Speed control.

2.1 Valve PWM control.

2.2 Pump motor speed control.

Channel 4

Selection is decided in SETTINGS between: 1. OnOff control.

2. Speed control.

2.1 Valve PWM control.

2.2 Pump motor speed control.

Remarks:

17

ATLET Menu tree Level 1

Level 2

Level 3

Level 4

Level 5

Level 6

Remarks:

Example 1 - tiller application Lift channel is analog, with valve PWM output. Inputs are decided in Atlet menu/Calibrate/Lift menu. When the display requests "full raise" the proportional pushbutton connected to J9 (lift) is activated by the engineer followed by ENT. Cortex then recognises this input as the raise input. The display requests "full lower" and the operator pushes the button connected to J8 (lower).

Cortex has now detected which inputs are used for raise and lower, and has also stored at which input levels full output should be given.

Output type is selected in Atlet menu/Settings/Hydraulics/Lift. First of all, speed control is selected. Now, further settings are needed. In this case, a porportional valve will be controlled by HVC 1.

The engineer selects valve speed control. Fixed outputs for contactor prop valve and dir valve are hardcoded. Output relations to dead zone passing and to calibrated maximum input are entered.

Channel 2 is 'digital', with onoff valve control. No input calibrations need to be done, since output is defined as 'onoff'. Hardcoded definitions for input and output associations take effect.

Example 2 - rider stacker Lift channel is analog, with joystick and pump motor speed control. Input calibration is carried out as in example 1. Cortex recognizes the a 'combined' raise/lower control from the voltage levels read during calibration.

Output setting s are set to 'speed control' and 'motor'. Raise command is sent to hardcoded adress in PMC, lower command is sent to HVC 1.

1

Language Tree Level 1 SELECT LANGUAGE: English ^v Svenska Deutsch Francais Custom

Level 2

Level 3

Level 4

Level 5

Remarks:

1

Monitor menu Level 1 MONITOR MENU: < Exit

Level 2 >

MONITOR MENU: < Traction

>

TRACTION: ENT / v -> Drive Monitor ^ v TRACTION: Temp Monitor ^ v

MONITOR MENU: < Pump

>

MONITOR MENU: < Steering

>

Level 3

Remarks:

ENT ->

xxxxrpm +/-iii A

"xxxx" = motor speed in rpm; "iii" = motor current

C: +/-ttt degC M: +/-TTT degC

"ttt" = controller temperature; "TTT" = motor temperature

ENT ->

xxxxrpm ENT / v -> +/-iii A v^ C:ttt M:TTT degC

Angle:

xx

ENT / v -> Record angle

not implemented yet

MONITOR MENU: < Wire guide

>

MONITOR MENU: < In/Out

>

ENT / v -> IN/OUT: ATC inputs:

^v

ENT / v ->

Accelerator Raise1 Raise2 Lower1 Lower2 Belly BellyInv TillerUpD Horn Dig_in1 Dig_in2 Dig_in3 Dig_in4 Dig_in5

xxx xxx xxx xxx xxx x x x x x x x x x

2

Monitor menu Level 1

Level 2

Level 3

IN/OUT: TMC inputs:

^v

ENT / v ->

IN/OUT: HVC inputs:

^v

ENT / v ->

IN/OUT: EPS inputs:

^v

ENT / v ->

IN/OUT: ATC int/out:

^v

ENT / v ->

Remarks:

Dig_in1 Dig_in2 Dig_in3 Dig_in4 Dig_in5 Dig_in6 Dig_in7

x x x x x x x

Dig_in1 Dig_in2 Dig_in3 A_in 1

x x x xxx

Lift int Speed int Safety int Max spd Forward Reverse Brake Liftstop

x x x xxx x x x x

Reset menu Level 1 RESET: All users

^v

ENT ->

RESET: Options

^v

ENT ->

RESET: Settings

^v

ENT ->

RESET: Calibration

^v

ENT ->

RESET: Logs

^v

ENT ->

Level 2 Reset all users?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT Reset options?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT Reset settings?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT Reset calib?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT Reset logs?

0:no 1:yes Successful reset Press ENT Reset aborted!

Press ENT

Level 3

Level 4

Level 5

Remarks:

SERVICE MANUAL Machine: Manual No:

PLP 119002

Edition 2007A

11 Brake and drive system Design and function ..................................................................................................... 11.3 Electric brake ......................................................................................................11.3 Repair instructions ....................................................................................................... 11.4 Electric brake ......................................................................................................11.4 Service ......................................................................................................................... 11.4 Replacing the brake disc (–2006w46) .......................................................................... 11.4 Replacing the brake disc (2006w47–) .......................................................................... 11.5 Emergency release ...................................................................................................... 11.6

SERVICE MANUAL

11.2

SERVICE MANUAL

Brake and drive system / Design and function / Electric brake

11.3

Edition 2007A

11 Brake and drive system Design and function Electric brake PLL is equipped with an electric brake. The electric brake is a safety brake with two friction surfaces. The braking torque is produced by spring pressure. The brake is activated when the voltage over the coil is lost, i.e. the truck is braked when it is without voltage.

When the brake is activated the springs press on the plate, which is pressed axially to the rotor. When the brake is to be released the coil is supplied with battery voltage. The magnetic field created between the plate and the magnetic part allows the rotor to rotate freely.

The brake is activated by the TMC and EPS via the ATC (see also wiring diagram).

SM_PLP_11_119002_2007A.fm

SERVICE MANUAL

11.4

Brake and drive system / Repair instructions / Electric brake

Repair instructions Electric brake Service The brake does not need adjusting.

When serviced the gap between the magnetic parts should be measured to ensure that the brake disc is not worn.

A

Figure 11.1

The gap A can be measured with the brake fitted (figure 11.1).

Warning!

The brake disc is worn out and should be replaced if the measured gap is greater than 0.6 mm!

Replacing the brake disc (–2006w46) 1.

Disconnect the electrical connection to the magnetic part.

2.

Release the three retaining screws holding the magnetic part, and carefully lift off.

Clean the magnetic part.

3.

Lift off the brake disc and clean all the surfaces.

4.

Fit the new brake disc and refit the magnetic part. Tighten the three retaining screws to 9.5 Nm.

5.

Reconnect the electrical connection to the magnetic part.

Warning!

Check that you have a safe braking capacity.

SERVICE MANUAL

Brake and drive system / Repair instructions / Electric brake

11.5

Replacing the brake disc (2006w47–)

C B Figure 11.2 Electric brake (2006w47–)

1.

Disconnect the electrical connections to the magnetic part.

2.

Undo the three retaining screws, pos B in figure11.2.

3.

Dismantle the brake by unscrewing 3 screws, pos C.

4.

Lift out the brake disc and clean the magnetic part and brake plate.

5.

Mount the new brake disc and refit the magnetic part. Tighten the three retaining screws at 9.5 Nm.

6.

Reconnect the electrical connections to the magnetic part.

Warning!

Check that you have a safe braking capacity.

SERVICE MANUAL

11.6

Brake and drive system / Repair instructions / Electric brake

Emergency release The brake can be released manually if necessary.

Note!

If the brake is released manually there will be no functioning parking or emergency brake. Never leave a machine with a manually released brake!

Figure 11.3

To manually release the brake, screw in two screws (M6x55) in the two marked holes (figure 11.3).

SERVICE MANUAL