Atlet Forklift X-90 SERVICE MANUAL 005872 – PDF DOWNLOAD

Description

Atlet Forklift X-90 SERVICE MANUAL 005872 – PDF DOWNLOAD

FILE DETAILS:

Atlet Forklift X-SERVICE MANUAL 005872 – PDF DOWNLOAD

Language : English
Pages :324
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Atlet Forklift X-SERVICE MANUAL 005872 – PDF DOWNLOAD

1 General information and technical data 21
11 Introduction 21
111 General information X-90 series 21
12 How to use the manual 22
122 Symbol key 22
13 Tips before next step 23
131 Lifting points 23
132 Safety risks when working on fork trucks 24
133 Environmentally hazardous waste – environment 24
134 Handling 25
135 Trouble shooting 25
14 Type designations 26
15 Dimensions and weights 30
151 Dimensions XJN / XSN 30
152 Dimensions XML 31
153 Dimensions XLL 32
154 Dimensions XTF 33
16 Component specification 34
17 Tightening torque 37
171 Conversion table 38
172 Bolt types and tensile grades 39
18 Lubrication chart and recommended intervals 40
181 Lubrication chart XJN / XSN / XML 40
182 Lubrication chart XTF 42
183 Lubrication chart XLL 44
184 Symbol explanations, lubrication chart 45
185 Recommended oil and grease types 46
181 Recommended replacement 46
19 Colour codes and technical descriptions 47
192 Colour of the truck in accordance with NCS colour codes 47
191 Colour codes for Atlet wiring diagrams 47
192 Designations for electrical components 48
193 Technical abbreviations 49
2 Special tools 53
21 List of tools 53
3 Service 57
31 Introduction 57
32 Service inspection list 58
321 Chassis 58
322 Drive unit 59
323 Mast 60
324 Steering 61
325 Brake 61
326 Hydraulic system 62
327 Electrical system 63
33 Code explanations 64
331 Chassis 64
332 Mast 65
333 Drive unit 65
334 Steering 66
335 Brake unit 66
336 Hydraulic system 67
337 Electrical system 68
4 Chassis 71
41 Introduction 71
411 Machine cover 71
412 Tightening torque 72
413 Overhead guard 73
414 Panels 73
42 Castor wheel 74
421 Description 74
422 Dismantling 74
423 Dismantling 75
424 Assembly 75
425 Adjusting the angle of the truck 76
43 Driver’s seat 77
431 Description 77
431 Settings 77
44 Replacing the battery rollers 79
45 Replacing the load wheel, bogie wheel 80
451 Dismantling 80
452 Assembly 80
46 Replacing the load wheel, single wheel 81
461 Dismantling 81
462 Assembly 81
5 Drive unit 85
51 Introduction 85
52 Dismantling and assembling the drive unit 86
53 Gearbox 89
531 First service 89
532 Preventive maintenance 89
54 Drive motor, general instructions 90
541 Storage of machines and motors 90
542 First service 90
543 Preventive maintenance 90
544 Dismantling, assembling the motor 91
55 Reconditioning the motor 92
551 Series motor, older type, used together with MOS-90 92
552 Separate field-magnetised motor, new type, used together with Sepex 94
553 Motor bearings 96
554 Brush holders 96
555 Overhaul of commutator and replacing the carbon brushes 96
556 Stator housing 98
557 Assembly 98
558 Reasons for burned motors: 98
56 Trouble shooting chart 99
6 Mast105
61 Introduction105
611 General105
62 Fork creep106
621 All trucks with masts106
63 Dismantling and assembling the masts106
631 General106
632 Assembling, dismantling older models106
633 Assembling, dismantling new models106
64 Mast system older models107
641 Adjusting the brass lugs107
642 Adjusting the mast top107
643 Dismantling the DTFV mast108
644 Dismantling the TFV mast110
645 Dismantling the TV mast112
646 Dismantling the DT mast114
647 Dismantling the T mast116
65 Mast system new model118
651 Adjusting the mast118
652 Dismantling the DTFV mast118
653 Dismantling TFV mast, new model120
654 Dismantling TV mast, new model122
655 Dismantling T mast, new model124
66 Fork carriage126
661 Adjusting, older models126
662 Adjusting, new models127
663 Dismantling127
664 Dismantling the fork carriage XTF128
665 Assembling the fork carriage XTF130
666 Checking the fork carriage XTF truck130
667 Overload clutch131
67 Forks132
671 Adjusting forged forks132
672 Adjusting welded forks132
673 Fork test133
68 Checking the lift chains135
681 Regular maintenance136
682 Re-fitting the chains136
69 Straddle lift137
691 Adjusting (=>2002w49)137
692 Dismantling and adjusting, TV, TFV, DTFV (=>2002w49)138
693 Straddle lift (2002w50=>)140
610 Side stabilisers141
6101 Dismantling and assembling (=>2002w45)141
6102 Assembling (=>2002w45)142
6103 Checking the side stabiliser (=>2002w45)143
6104 Adjusting the side stabilisers (=>2002w45)143
6105 Side stabilisers (2002w46=>)144
611 Push rods145
6111 Adjusting XLL145
612 Lift cylinders147
6121 Adjusting the cylinder attachment in the mast, older version147
6122 Adjusting cylinder attachment, newer version148
613 Trouble shooting chart149
7 Steering153
71 Introduction153
72 Mechanical steering153
721 Main shaft, general153
722 Steering column, dismantling and assembling153
723 Steering chain steering column – intermediate gear, dismantling155
724 Steering chain intermediate gear – drive unit, dismantling155
725 Steering chains, assembly155
726 Intermediate gear, dismantling156
727 Intermediate gear, assembly156
73 Mechanical steering with auxiliary servo (Keltronic)157
731 Servo motor, dismantling157
732 Replacing the carbon brushes158
733 Servo sensor, general158
734 Servo sensor, inspection and trouble shooting158
735 Servo sensor, measurement check159
736 Control unit, general160
737 Control unit, settings162
738 Control unit, check163
74 Electronic steering (ACC)165
749 Servo steering unit, functions165
7410 Servo steering unit, settings166
7411 Factory setting, electric steering168
7412 Servo steering unit, diagnostics168
7413 Trouble shooting169
7414 Check tachometer170
7415 Servo motor, replacing carbon brushes171
8 Hydraulic system177
81 Functional description177
811 Introduction177
812 XSN / XJN / XML / XTF trucks177
813 XLL truck179
82 Hydraulic system – general regulations180
821 Installation180
822 Connections180
823 Start up180
824 Installation instruction for pipe couplings181
825 Hydraulic oil, changing/draining184
83 Oil change185
831 XSN / XJN / XML / XTF trucks185
832 XLL truck185
84 Air filter, replacing186
841 XSN / XJN / XML / XTF trucks186
842 XLL truck186
85 Filter insert, replacing187
851 XSN / XJN / XML / XTF trucks187
86 Hydraulic unit XLL truck188
862 Hydraulic unit XLL, dismantling188
863 Motor for hydraulic unit XLL, dismantling and assembling188
864 Repair of lift motor and replacement of carbon brushes, XLL truck189
865 Lowering valve, dismantling and assembling189
866 Overflow valve, adjusting189
87 Valves, XSN / XJN / XML / XTF190
871 Lowering brake valve, general190
872 Lowering brake valve, dismantling and assembling190
873 Setting the lowering brake valve191
874 Hose rupture valve, general192
875 Hose rupture valve, dismantling and assembling192
876 Setting the hose rupture valve193
88 Hydraulic valve, general194
887 Hydraulic valve, dismantling and assembling194
89 Hyrdaulic motor XJN / XJN196
891 Dismantling196
810 Stabiliser cylinders XSN / XJN198
8101 Dismantling and assembling198
8102 Spring unit, dismantling and assembling199
8103 Dismantling and assembling, seals200
811 Hydraulic diagram201
9 Lift cylinders215
91 Introduction215
92 Free-lift cylinder TFV / DTFV older model216
921 Dismantling and assembling216
922 Dismantling and assembling to: W-9638216
923 Dismantling and assembling from: W-9639218
93 Free-lift cylinder TFV / DTFV new model220
931 Dismantling and assembling220
932 Dismantling and assembling220
94 Lift cylinder TV/ TFV/ DTFV older model222
941 Dismantling and assembling222
942 Dismantling and assembling to: W-9638223
943 Dismantling and assembling from: W-9638224
95 Lift cylinder TV/ TFV/ DTFV new model226
954 Dismantling and assembling226
955 Dismantling and assembling228
96 Lift cylinder 100 DT / 125 DT to: W-9638229
961 Dismantling and assembling229
962 Dismantling and assembling231
97 Lift cylinder 100 DT / 125 DT from: W-9639232
971 Dismantling and assembling232
972 Dismantling and assembling232
98 Lift cylinder 100 T / 125 T234
981 Dismantling and assembling234
982 Dismantling and assembling235
99 Lift cylinder 160 T new model236
991 Dismantling and assembling236
992 Dismantling and assembling236
910 Lift cylinder, straddle lift238
9101 Dismantling and assembling, (P/N 057869)238
9102 Dismantling and assembling238
9103 Dismantling and assembling, (P/N 060061)240
9104 Dismantling and assembling240
911 Lift cylinders XLL242
9111 Dismantling and assembling242
9112 Dismantling and assembling242
912 Bleeding the cylinders244
9121 Bleeding TV/ TFV/ DTFV to: W-9638244
9122 Bleeding models from: W-9639244
10 Electrical system251
101 Introduction251
102 Safety procedures252
103 Routine test of the insulation resistance253
1031 Introduction253
1032 Routines for insulation testing of all truck models253
1033 Insulation test of a newly charged battery mounted in the truck:253
104 Battery maintenance254
1041 Truck driver’s responsibility254
1042 Foreman’s responsibility254
1043 Checking of the battery fluid254
105 Drive motor255
1051 Dismantling and assembling255
1052 Replacing the drive motor cable255
106 Fork drive motor, XTF truck256
1061 Dismantling and assembling256
1062 Replacing the carbon brushes256
1063 Replacing the coupling between motor and gear256
1064 Electric cable to fork drive motor, replacing256
107 Speed controller to machine number X14000 (MOS 90)258
1071 Description258
1072 Dismantling of speed controller258
1073 Microswitches, complete check258
1074 Microswitches, simple check259
1075 Microswitches, replacing259
1076 Speed controller, adjusting260
1077 Thottle, replacing261
1078 Speed control, complete check261
1079 Speed control, simple check261
108 Speed controller from machine number X14000 (SEPEX)262
1081 Description262
1082 Dismantling of speed controller262
1083 Speed controller, adjusting262
109 Drive regulator264
1091 Dismantling, assembling the drive regulator264
1010 Drive regulator MOS 90265
10101 Safety procedures265
10102 Checking the failsafe system, drive regulator266
10103 Settings, drive regulator266
10104 Settings for checking/fault finding of drive regulator268
10105 Input status, drive regulator269
10106 Trouble shooting chart, drive regulator270
10107 Connections and voltage values280
1011 Drive regulator Curtis/Sepex 1243 version 4324281
10111 Introduction281
10112 General description281
10113 Technical description281
10114 Hand terminal283
10115 Special program285
10116 Adjusting instructions285
10117 Factory settings286
10118 Possibility of separate adjustments:290
10119 Parameter selection M1 – M4290
1012 Function and Installation checking291
10121 Trouble shooting by means of LED:292
10122 Trouble shooting by means of Test menu294
10123 Brake function295
10124 Left foot switch295
10125 Specifications295
1013 Side stabilisers296
10131 Adjusting297
1014 Wiring diagram298
11 Brake system303
111 Brake system to machine number X 14000303
1111 Description303
1111 Brake unit305
1112 Brake drum305
1113 Brake shoes, replacing306
1114 Dismantling, older version306
1115 Dismantling, new version306
1116 Master cylinder308
1117 Brake cylinder308
1118 Brake fluid and bleeding309
1119 Hand brake wire, replacing on older version with wire through brake shoes309
11110 Hand brake wire, replacing on new versions with wire that stops at the brake shoes310
11111 Adjusting of the brake pedal’s push rod and height310
11112 Adjusting the brake, older version312
11113 Adjusting the brake, new version313
11114 Adjusting the foot brake314
11115 Emergency brake system314
1111 Hydraulic unit, emergency brake to W 9640314
1112 Hydraulic unit, emergency brake from W 9640315
1113 Pressure switch, version to W 9640316
1114 Pressure switch, version from W 9640 to W 9735316
1115 Pressure switch version from W9735 for X 14000317
1116 Adjusting the spring brake cylinder317
1117 Trouble shooting chart, hydraulic unit318
112 Brake system from machine number X 14000319
1121 Description319
1122 Dismantling/assembling, brake pedal320
1121 Electric brake 1 stage, 1 disc320
1122 Dismantling/assembling, electric brake320
1123 Adjusting the electric brake322
113 Left-foot switch323
1131 Dismantling, assembling the left-foot switch323
1132 Adjusting the left-foot switch323
1133 Preventive maintenance323

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