Atlet P Series PLP 200 & PLP 250 Service Manual – PDF DOWNLOAD
DESCRIPTION:
Atlet P Series PLP 200 & PLP 250 Service Manual – PDF DOWNLOAD
Machine: PLP
Manual No 119002
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.
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.
Scope of the P series:
The manual covers the low lifters PLP 200 and PLP 250.
The manual covers the low lifters PLP 200 and PLP 250.
How to use the manual:
Structure:
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.
TABLE OF CONTENTS:
Atlet P Series PLP 200 & PLP 250 Service Manual – PDF DOWNLOAD
01...................................................................... 1 1 General information and technical data............................ 1 Scope of Service Manual......................................... 3 General..................................................... 3 Scope of the P series....................................... 3 How to use the manual........................................... 4 Structure................................................... 4 Symbol key.................................................. 4 Safety instructions............................................. 5 General..................................................... 5 Gas springs in platform and steering arm.................... 6 Lifting the truck........................................... 6 Welding on the truck........................................ 8 Atlet AB takes care of the environment...................... 8 Environmental impact........................................ 8 Waste....................................................... 8 Preparations.................................................... 9 Service..................................................... 9 Trouble shooting............................................ 9 Data PLP........................................................ 10 Designations................................................ 10 Dimensions and weights...................................... 14 Component specification..................................... 16 Recommended consumable materials................................ 17 Oil and grease.............................................. 17 Standards and abbreviations..................................... 18 Screws...................................................... 18 Tightening torque, hydraulic couplings...................... 20 Conversion tables........................................... 20 Standard abbreviations...................................... 21 Colour of the truck......................................... 21 Colour codes, cabling....................................... 22 Designations................................................ 22 02...................................................................... 25 2 Special tools..................................................... 25 Special tools PLP............................................... 27 Introduction................................................ 27 List of tools............................................... 27 03...................................................................... 29 3 Service........................................................... 29 Regular maintenance............................................. 31 Introduction................................................ 31 Safety...................................................... 31 Recommendation.............................................. 31 Daily inspection............................................ 32 Weekly inspection (30 hours of operation)................... 33 First service............................................... 33 Main service................................................ 33 Extra service inspections................................... 34 Check list, service inspection.............................. 35 Code explanation............................................ 39 Lubrication chart........................................... 43 Specific instructions........................................... 45 Traction motor.............................................. 45 Gearbox..................................................... 45 Lift chains and forks....................................... 46 Hydraulic oil............................................... 47 Emergency stop.............................................. 47 Recommended replacement..................................... 48 Storage of machines and motors.............................. 48 04...................................................................... 49 4 Chassis........................................................... 49 Design and function............................................. 51 Scope....................................................... 51 Machine housing............................................. 51 Covers and panels........................................... 51 Castor wheel................................................ 52 Repair instructions............................................. 53 Covers and panels........................................... 53 Castor wheel................................................ 54 Battery..................................................... 56 05...................................................................... 57 5 Drive unit........................................................ 57 Design and function............................................. 59 Introduction................................................ 59 Traction motor.............................................. 59 Gearbox..................................................... 59 Repair instructions............................................. 60 Preparations................................................ 60 Dismantling the drive unit housing.......................... 60 Traction motor.............................................. 61 Gearbox..................................................... 61 Drive wheel................................................. 63 Diagnostics and trouble shooting................................ 64 Trouble shooting chart...................................... 64 06...................................................................... 67 6 Mast system....................................................... 67 Design and function............................................. 69 Lift system................................................. 69 Repair instructions............................................. 70 Fork carriage, general...................................... 70 Adjusting the fork carriage................................. 70 Diagnostics and trouble shooting................................ 72 Trouble shooting chart...................................... 72 07...................................................................... 73 7 Steering.......................................................... 73 Design and function............................................. 75 General..................................................... 75 Steering.................................................... 75 Servo unit (-2005w19)....................................... 75 Servo unit (2005w20-)....................................... 77 Repair instructions............................................. 79 Cleaning.................................................... 79 Tiller arm head (-2007w27).................................. 79 Tiller arm head (2007w28-).................................. 80 Tiller arm (2007w28-)....................................... 84 Replacing the steering belt................................. 85 Adjusting the steering belt................................. 85 Adjustment, limit switch.................................... 85 Adjustment, electrical steering............................. 86 Servo steering (2006w15-)................................... 89 08...................................................................... 93 8 Hydraulic system.................................................. 93 Design and function............................................. 95 General..................................................... 95 Electric solenoid valve..................................... 95 Hydraulic diagram........................................... 96 Repair instructions.............................................100 Hydraulic system............................................100 Hydraulic oil, changing/draining............................102 Motor, hydraulic unit.......................................104 Solenoid valve..............................................106 Installation instruction for pipe couplings.................108 Diagnostics and trouble shooting................................111 Symptom and Action..........................................111 09......................................................................113 9 Lift cylinders....................................................113 Design and function.............................................115 Introduction................................................115 Lift cylinder...............................................115 10......................................................................117 10 Electrical System................................................117 Design and Function.............................................121 General.....................................................121 Repair Instructions.............................................123 General.....................................................123 Battery.....................................................124 General Handling............................................126 Connectors in Cold Storage Rooms............................128 Drive and Valve Controller..................................129 Wiring Diagram..............................................130 Insulation Resistance.......................................131 Main Controller Unit ATC, Handling..........................131 ATC Logic...................................................149 Download....................................................153 ATC Connector...............................................155 Digital I/Os................................................155 Cold Resistance Values......................................157 Fuses.......................................................157 Diagnostics and Trouble Shooting................................158 Truck Remote ACcess, TRAC...................................158 Illustrated instructions are attached to the TRAC cable.....158 Error Codes.................................................159 Appendix 1, Summary menu tree...................................175 11......................................................................206 11 Brake and drive system...........................................206 Design and function.............................................208 Electric brake..............................................208 Repair instructions.............................................209 Electric brake..............................................209
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