Atlet T Series Truck TP TL TS Service Manual – PDF DOWNLOAD

Description

Atlet T Series Truck TP TL TS Service Manual – PDF DOWNLOAD

DESCRIPTION:

Atlet T Series Truck TP TL TS Service Manual – PDF DOWNLOAD

Machine:T
Manual No: 005879

Introduction :

This manual describes the service procedures for ATLET’s low lifters, pickers and stackers in the T truck series. Use the manual for quick and correct service of respective truck models. The manual describes models manufactured from November 1991. You may find contradictions in the manual compared to the models supplied due to optional designs, product development, and the like.

General information TP /TL /TS :

• The trucks have been developed with the driver’s working environment in focus and in accordance with a completely new customer-orientated concept.
• TP is built according to a module system, where the chassis module is the same for all alternatives.
• The steering modules are the steering wheel or steering arm.
• The driver module has two alternatives, either fixed or driver-lifting. The load carrying module is available in two versions, low lifters or fork lifters.
• TL and TS are available in two versions, with or without driver platform.
• New time-saving solutions reduce the time required for servicing. The drive motor, hydraulic motor and other service points are easily accessible. A large number of common parts ensure a high degree of service.

How to use the manual :

• The manual is arranged according to the same principles as ATLET’s spare part catalogues, i.e. a system consists of 12 sections, where sections 4 -12 contain information limited to a specific part of the truck, e.g. Master (section 6) and Hydraulic system (section 8). Sections 1 – 3 in this manual contain more comprehensive information regarding technical data, general service instructions and tools.
• The main principle for extra accessories is to place them under the respective sections. Otherwise they are placed under section 12 “Miscellaneous”. For this reason section 12 does not always contain any information in the Service Manual.
• For specific problems or information about procedures, look in the main index for the correct section.

TABLE OF CONTENTS:

Atlet T Series Truck TP TL TS Service Manual – PDF DOWNLOAD

01.............................................................................................  1
	1 General information and technical data...................................................  1
		1.1 Introduction.......................................................................  5
		1.2 General information TP /TL /TS.....................................................  6
		1.3 How to use the manual..............................................................  7
			1.3.1 History......................................................................  7
			1.3.2 Symbol key...................................................................  7
		1.4 Tips before next step..............................................................  8
			1.4.1 Lifting points...............................................................  8
			1.4.2 General safety risks when working on fork trucks............................. 10
			1.4.3 Environmentally hazardous waste - environment................................ 10
			1.4.4 Handling..................................................................... 11
			1.4.5 Trouble shooting............................................................. 11
		1.5 Type designations TL/TP/TS......................................................... 12
			1.5.1 Type plate TL................................................................ 13
			1.5.2 Type plate TP................................................................ 13
			1.5.3 Type plate TS (-2006w36)..................................................... 14
			1.5.4 Type plate TS (2006w37-)..................................................... 14
		1.6 Dimensions and weights............................................................. 16
		1.7 Component specification............................................................ 19
			1.7.1 Drive motor.................................................................. 19
			1.7.2 Electric brake............................................................... 19
			1.7.3 Gearbox...................................................................... 19
			1.7.4 Hydraulic unit (motor and pump).............................................. 20
			1.7.5 Control system for motor..................................................... 20
			1.7.6 Battery...................................................................... 20
			1.7.7 Fuses........................................................................ 21
		1.8 Tightening torque.................................................................. 22
			1.8.1 Tightening torque standard................................................... 22
			1.8.2 Conversion table............................................................. 23
			1.8.3 Tensile grade, screws........................................................ 24
		1.9 Lubrication chart.................................................................. 26
		1.10 Colour codes for Atlet’s wiring diagrams.......................................... 30
		1.11 Colour codes according to NCS..................................................... 31
		1.12 Designations for electrical components............................................ 32
			1.12.1 Designation electrical components TL........................................ 32
			1.12.2 Designations, electrical components TP/TS................................... 34
			1.12.3 Recommended oil and grease types............................................ 35
			1.12.4 Recommended replacement..................................................... 35
02............................................................................................. 37
	2 Special tools............................................................................ 37
		2.1 List of tools...................................................................... 39
03............................................................................................. 43
	3 Service.................................................................................. 43
		3.1 Introduction....................................................................... 45
		3.2 Service inspection list T.......................................................... 46
		3.3 Code explanations.................................................................. 54
04............................................................................................. 59
	4 Chassis.................................................................................. 59
		4.1 Introduction....................................................................... 61
			4.1.1 Gas springs in platform and steering arm..................................... 61
			4.1.2 Protection for hydraulic hose................................................ 62
		4.2 Chassis TP......................................................................... 63
			4.2.1 Overhead guard front/rear, TP................................................ 63
			4.2.2 Battery cover TP............................................................. 64
		4.3 Driver’s platform TPD/TPC.......................................................... 67
			4.3.1 Dismantling the driver’s platform (version to November 99)................... 67
			4.3.2 Replacing the wear rails (version to November 99)............................ 69
			4.3.3 Assembling and adjusting the driver’s platform (version to November 99)...... 70
			4.3.4 Dismantling the driver’s platform (version from November 99)................. 71
			4.3.5 Replacing the guides (version from November 99).............................. 73
			4.3.6 Assembling and adjusting the driver’s platform (version from November 99).... 74
		4.4 Chassis TL......................................................................... 75
		4.5 Chassis TS......................................................................... 77
		4.6 Platform TLP/TS (2002w34=>)........................................................ 79
		4.7 Panels / Mats...................................................................... 80
			4.7.1 Dismantling, assembling the panels........................................... 80
		4.8 Castor wheel....................................................................... 83
			4.8.1 Replacing the castor wheel / bearing......................................... 85
05............................................................................................. 87
	5 Drive unit............................................................................... 87
		5.1 Introduction....................................................................... 89
		5.2 Dismantling, assembling the drive unit............................................. 90
		5.3 Drive motor, general instructions.................................................. 91
		5.4 Reconditioning the motor........................................................... 95
		5.5 Replacing the gears in the gearbox.................................................103
		5.6 Replacing the drive wheel..........................................................104
		5.7 Replacing the drive shaft seal.....................................................105
		5.8 Trouble shooting chart.............................................................106
06.............................................................................................107
	6 Mast.....................................................................................107
		6.1 Introduction.......................................................................109
		6.2 Mast system TS.....................................................................110
		6.3 Dismantling and assembling the masts, general......................................111
			6.3.1 Assembling, dismantling older models.........................................111
			6.3.2 Assembling, dismantling new models...........................................111
		6.4 Mast system new model..............................................................112
			6.4.1 Dismantling the DTFV mast....................................................112
			6.4.2 Dismantling the TFV mast.....................................................114
			6.4.3 Dismantling the TV mast......................................................116
			6.4.4 Dismantling the T mast.......................................................118
		6.5 Mast system older models...........................................................120
			6.5.1 Adjusting the brass lugs.....................................................120
			6.5.2 Adjusting the mast top.......................................................121
			6.5.3 Dismantling the DTFV mast....................................................121
			6.5.4 Dismantling the TFV mast.....................................................124
			6.5.5 Dismantling the TV mast......................................................126
			6.5.6 Dismantling the DT mast......................................................128
			6.5.7 Dismantling the T mast.......................................................130
		6.6 Fork carriage......................................................................132
			6.6.1 Adjusting, new model.........................................................132
			6.6.2 Adjusting, older models......................................................133
			6.6.3 Dismantling..................................................................133
		6.7 Forks..............................................................................135
			6.7.1 Adjusting forged forks.......................................................135
			6.7.2 Adjusting welded forks.......................................................135
			6.7.3 Fork test....................................................................136
		6.8 Checking the lift chains...........................................................138
			6.8.1 Regular maintenance..........................................................139
			6.8.2 Re-fitting the chains........................................................139
		6.9 Straddle lift......................................................................140
			6.9.1 Adjusting (old model)........................................................140
			6.9.2 Dismantling and assembling, T, TF, DT, DTF (old model).......................140
			6.9.3 Dismantling and adjusting, TV, TFV, DTFV (=>2002w49).........................142
			6.9.4 Straddle lift (2002w50=>)....................................................144
		6.10 Lift cylinders....................................................................147
			6.10.1 Adjusting the cylinder attachment in the mast, older model..................147
			6.10.2 Adjusting the cylinder attachment in the mast, new model....................148
		6.11 Low-lifting fork carriage.........................................................149
			6.11.1 Dismantling the forks carriage TL...........................................151
			6.11.2 Dismantling the fork carriage TP............................................152
			6.11.3 Adjusting the push rods TL..................................................153
			6.11.4 Compact bogie TP............................................................154
			6.11.5 Dismantling of the load wheel in bogie for TL...............................155
			6.11.6 Assembling the load wheel in bogie for TL...................................155
			6.11.7 Adjusting the push rod spring TL............................................156
			6.11.8 Dismantling the cup springs for the bogie movement TL.......................158
			6.11.9 Adjusting the slide lugs in the fork carriage...............................159
		6.12 Side shift........................................................................160
			6.12.1 Dismantling.................................................................160
			6.12.2 Assembly....................................................................161
			6.12.3 Adjusting the end position switch...........................................161
07.............................................................................................163
	7 Steering.................................................................................163
		7.1 Introduction.......................................................................165
		7.2 Mechanical steering................................................................166
			7.2.1 Adjusting the steering chain TP and inner steering chain TL/TS...............166
			7.2.2 Adjusting the steering arm / wheel...........................................167
			7.2.3 Adjusting the outer chain TLL/TSL............................................168
			7.2.4 Replacing the inner chain TL/TS, steering chain TP...........................168
			7.2.5 Replacing the steering chain TLL/TSL.........................................168
			7.2.6 Adjusting straight steering TP...............................................168
			7.2.7 Adjusting the straight steering chain indicating TP..........................168
			7.2.8 Inner steering shaft, TL/TS..................................................169
			7.2.9 Outer steering shaft.........................................................169
		7.3 Electronic steering TP.............................................................171
			7.3.1 Servo steering unit, functions...............................................171
			7.3.2 Servo steering unit, settings................................................173
			7.3.3 Servo steering unit, diagnostics.............................................175
			7.3.4 Trouble shooting.............................................................176
			7.3.5 Check tachosensor............................................................177
		7.4 Servo motor TP/TS, replacing carbon brushes........................................178
		7.5 Electronic steering TS.............................................................179
			7.5.1 Steering servo unit, functions...............................................179
			7.5.2 Servo steering unit, settings................................................181
			7.5.3 Servo steering unit, diagnostics.............................................182
			7.5.4 Adjusting, electronic steering...............................................184
		7.6 Repair instructions, tiller head...................................................187
			Cleaning...........................................................................187
			Tiller head (new version)..........................................................187
08.............................................................................................189
	8 Hydraulics...............................................................................189
		8.1 Introduction.......................................................................191
		8.2 Hydraulic system – general regulations.............................................200
			8.2.1 Installation.................................................................200
			8.2.2 Connections..................................................................201
			8.2.3 Start up.....................................................................201
			8.2.4 Installation instruction for pipe couplings..................................201
		8.3 Hydraulic unit, low-lifers TPL/TPD/TLL/TLP.........................................205
			8.3.1 Functional description.......................................................205
			8.3.2 Changing the oil and replacing the filter....................................206
			8.3.3 Changing the oil and replacing the hydraulic unit TPL / TPD..................210
			8.3.4 Dismantling the hydraulic unit...............................................211
			8.3.5 Dismantling the lift motor, replacing the carbon brushes, TLL/TLP............211
			8.3.6 Dismantling the lift motor, replacing the carbon brushes, TPL/TPD............212
		8.4 Adjusting..........................................................................214
			8.4.1 Adjusting the pressure limiting valve, TL....................................214
			8.4.2 Adjusting the pressure limiting valve, TP....................................215
			8.4.3 Adjusting the pressure limiting valve, TS....................................217
		8.5 Hydraulic unit TS / TPC / TPF......................................................218
			8.5.1 Functional description, lift lever TS........................................218
			8.5.2 Functional description TPC / TPF.............................................218
			8.5.3 Changing the hydraulic oil...................................................218
			8.5.4 Replacing the filter insert..................................................220
			8.5.5 Replacing the air filter.....................................................221
		8.6 Valves TS..........................................................................222
			8.6.1 Lowering brake valve, general................................................222
			8.6.2 Lowering brake valve, dismantling and assembling.............................222
			8.6.3 Setting the lowering brake valve.............................................223
			8.6.4 Hose rupture valve, general..................................................223
			8.6.5 Hose rupture valve, dismantling and assembling...............................224
			8.6.6 Setting the hose rupture valve...............................................225
			8.6.7 Hydraulic valve, general.....................................................225
			8.6.8 Hydraulic valve, dismantling and assembling..................................226
		8.7 Proportional valve TS..............................................................228
			8.7.9 General, proportional valve..................................................228
			8.7.10 Emergency lowering valve....................................................228
			8.7.11 Checking the potentiometer..................................................229
			8.7.12 Checking the steering unit, proportional valve..............................229
		8.8 Lift motor TS / TPF / TPC..........................................................231
			8.8.1 Dismantling..................................................................231
			8.8.2 Checking the lift motor Hesselman Haldex/Barnes..............................232
		8.9 Hydraulic unit side shift..........................................................234
			8.9.1 Dismantling..................................................................234
			8.9.2 Checking/replacing the carbon brushes........................................234
			8.9.3 Checking/replacing the oil and filter........................................236
			8.9.4 Assembly.....................................................................236
			8.9.5 Adjusting the safety valve...................................................236
			8.9.6 Trouble shooting chart.......................................................237
		8.10 Hydraulic diagram.................................................................238
09.............................................................................................257
	9 Lift cylinders...........................................................................257
		9.1 Introduction.......................................................................259
		9.2 Dismantling, assembling the lift cylinder TL/TP....................................267
		9.3 Adjusting the lift cylinder TL.....................................................268
		9.4 Dismantling the lift cylinder/side shift cylinder..................................269
		9.5 Assembling the lift cylinder/side shift cylinder...................................270
		9.6 Lift cylinders TS..................................................................272
		9.7 Free lift cylinder TFV / DTFV......................................................273
		9.8 Lift cylinder TV/ TFV/ DTFV (not 140)..............................................278
		9.9 Lift cylinder TV/ TFV/ DTFV (140)..................................................284
		9.10 Lift cylinder 100 T / 125 T.......................................................288
		9.11 Lift cylinder 140 T...............................................................291
		9.12 Lift cylinder, straddle lift......................................................293
		9.13 Bleeding the cylinders............................................................295
10.............................................................................................297
	10 Electrical system.......................................................................297
		10.1 Introduction......................................................................299
		10.2 Dismantling, assembling the drive regulator.......................................303
		10.3 MOS 90............................................................................305
			10.3.1 Safety procedures...........................................................305
			10.3.2 Checking the failsafe system, drive regulator...............................305
			10.3.3 Calibrator for MOS 90.......................................................307
			10.3.4 Adjustable functions MOS 90.................................................309
			10.3.5 Control and fault finding parameters MOS 90.................................310
			10.3.6 Settings, drive regulator...................................................310
			10.3.7 Settings for checking/fault finding of the drive regulator..................312
			10.3.8 Input status, drive regulator TL............................................313
			10.3.9 Input status, drive regulator TP............................................313
			10.3.10 Input status, drive regulator TS...........................................314
			10.3.11 Trouble shooting chart, drive regulator....................................315
		10.4 Introduction, Curtis / SEPEX 1243 version 4301....................................324
			10.4.1 CURTIS SEPEX drive regulator 1243 / version 4301............................324
			10.4.2 Technical description.......................................................325
			10.4.1 Function and Installation checking..........................................327
			10.4.1 Adjusting instructions......................................................328
			10.4.1 Hand terminal...............................................................333
			10.4.1 Special program.............................................................335
			10.4.2 Special Diagnostics.........................................................335
			10.4.3 Programming.................................................................335
			10.4.4 Trouble shooting Curtis 1243................................................336
			10.4.1 Trouble shooting by means of Test menu......................................337
			10.4.2 Transistor system Curtis Sepex..............................................338
			10.4.3 Attachment for insulator....................................................339
		10.5 Connections and voltage values MOS 90.............................................342
		10.6 Brake switch......................................................................344
			10.6.1 Inductive switch TL.........................................................344
			10.6.2 Mechanical microswitches TL/TP/TS...........................................344
		10.7 Wiring diagrams...................................................................345
11.............................................................................................347
	11 Speed control and brake systems.........................................................347
		11.1 Electric brake....................................................................349
			11.1.1 Electric brake 1 stage, 1 disc TL/TP/TS.....................................349
			11.1.2 Electric brake 2 stage, 1 disc TP...........................................351
			11.1.3 Electric brake (2002w42-2006w46)............................................352
			11.1.4 Adjusting the electric brake (-2002w42).....................................353
			11.1.5 Adjusting the electric brake (2002w42=>)....................................354
			11.1.6 Replacing the brake disc TS (2006w47-)......................................355
			11.1.7 Emergency release...........................................................355
		11.2 Switch............................................................................357
			11.2.1 Replacing the emergency switch TL/TS........................................357
			11.2.2 Replacing horn switch TL (older version)....................................357
			11.2.3 Replacing horn switch TL/TP/TS (older version)..............................358
			11.2.4 Replacing switch/parts in the handle........................................359
			11.2.5 Replacing the complete handle...............................................359
		11.3 Speed controller with potentiometer of older type.................................360
			11.3.1 Replacing the potentiometer.................................................360
			11.3.2 Adjusting the potentiometer.................................................360
		11.4 Speed controller with inductive sensor............................................362
			11.4.1 Spring in speed controller..................................................362
			11.4.2 Replacing the inductive sensor..............................................363
			11.4.3 Adjusting the inductive sensor..............................................364
		11.5 Speed controller for Sepex system.................................................365
			11.5.1 Replacing the speed controller..............................................365
		11.6 Speed limiting....................................................................367

ATLET T SERIES TRUCK TP TL TS SERVICE MANUAL – PDF DOWNLOAD:

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• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

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