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Atlet Truck A-Ergo A-Ergo TF Workshop Service Manual – PDF DOWNLOAD
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Atlet Truck A-Ergo A-Ergo TF Workshop Service Manual – PDF DOWNLOAD
Machine: A-Ergo
Manual No: 005975
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Description
Atlet Truck A-Ergo A-Ergo TF Workshop Service Manual – PDF DOWNLOAD
DESCRIPTION:
Atlet Truck A-Ergo A-Ergo TF Workshop Service Manual – PDF DOWNLOAD
Machine: A-Ergo
Manual No: 005975
General:
This manual describes the service procedures for ATLET stand-on stackers in the A-Ergo series. Use the manual for quick and correct service of respective truck models. The manual describes models manufactured from and including the introduction of AErgo at the end of 2002. You may find contradictions in the manual compared with the models supplied due to optional designs, upgrades and the like.
Scope of the A-Ergo model:
The stand-on stacker trucks in the A-Ergo series are available in a number of different variants with mast system, straddle lift, extendable stabilisors and telescopic forks (ATF).
How to use the manual
Structure:
The manual is built up according to the same principle as ATLET spare parts catalogues, with the truck divided into one subsystem per section.
Sections 1 – 3 in this manual contain comprehensive information regarding technical data, service instructions and tools.
Sections 4-12 in the manual contain information limited to a specific area in the truck concerning a description of the mechanical handling of different components. For example, Masts (section 6) and Hydraulic System (section 8).
With regard to software this is described under 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 Truck A-Ergo A-Ergo TF Workshop Service Manual – PDF DOWNLOAD
01.................................................................................... 1 1 General information and technical data.......................................... 1 Scope, service manual......................................................... 3 General................................................................... 3 Scope of the A-Ergo model................................................. 3 How to use the manual......................................................... 4 Structure................................................................. 4 History................................................................... 4 Symbol key................................................................ 4 Safety instructions........................................................... 5 General................................................................... 5 Lifting the truck......................................................... 6 Welding on the truck...................................................... 7 Taking the environment into consideration................................. 7 Preparations.................................................................. 8 Service................................................................... 8 Trouble shooting.......................................................... 8 Data A-Ergo................................................................... 9 Designations.............................................................. 9 Dimensions and weights.................................................... 14 Component specification................................................... 15 Recommended consumable material............................................... 16 Oil and grease............................................................ 16 Standards and abbreviations................................................... 17 Screws.................................................................... 17 Colour of the truck....................................................... 20 Colour codes, cabling..................................................... 20 Designations, electrical components....................................... 21 Standard abbreviations.................................................... 22 02.................................................................................... 23 2 Special tools................................................................... 23 Special tools A-Ergo.......................................................... 25 Introduction.............................................................. 25 List of tools............................................................. 25 03.................................................................................... 27 3 Service......................................................................... 27 Regular maintenance........................................................... 29 Introduction.............................................................. 29 Safety.................................................................... 29 Recommendation............................................................ 29 Daily service............................................................. 30 Weekly service (30 operating hours)....................................... 31 Service, 500 hours service interval....................................... 32 First service............................................................. 32 Check list, service inspektion............................................ 33 Code explanation.......................................................... 38 Lubrication chart......................................................... 42 Specific instructions......................................................... 45 Storage of machines and motors............................................ 45 Drive motor............................................................... 45 Gearbox................................................................... 46 Lift chains and forks..................................................... 47 Overhead guard............................................................ 47 Mast...................................................................... 48 Hydraulic oil............................................................. 49 Recommended replacement................................................... 49 04.................................................................................... 51 4 Chassis......................................................................... 51 Design and function........................................................... 53 Scope..................................................................... 53 Machine housing........................................................... 53 Overhead guard............................................................ 53 Arm rest and steering wheel panel......................................... 54 Covers and panels......................................................... 54 Foot plate................................................................ 54 Castor wheel.............................................................. 54 Repair instructions........................................................... 55 Overhead guard............................................................ 55 Arm rest.................................................................. 56 Steering wheel panel...................................................... 58 Covers and panels......................................................... 59 Foot plate................................................................ 59 Castor wheel.............................................................. 60 Adjusting the angle of the truck.......................................... 61 Battery................................................................... 62 05.................................................................................... 63 5 Drive unit...................................................................... 63 Design and function........................................................... 65 Introduction.............................................................. 65 Drive motor............................................................... 65 Gearbox................................................................... 65 Repair instructions........................................................... 66 Preparations.............................................................. 66 Drive motor............................................................... 66 Gearbox................................................................... 68 Reconditioning of the gearbox............................................. 70 Drive wheel, replacement.................................................. 75 Diagnosis and trouble shooting................................................ 76 Trouble shooting chart.................................................... 76 06.................................................................................... 79 6 Mast system..................................................................... 79 Design and function........................................................... 81 Mast system............................................................... 81 Fork carriage............................................................. 82 Fixed forks........................................................... 82 Laterally adjustable forks............................................ 82 Telescopic forks (TF)................................................. 83 Overload clutch, telescopic forks (TF)................................ 83 Fork drive motor, telescopic forks (TF)............................... 83 Straddle lift............................................................. 84 Side stabilisers.......................................................... 85 Repair instructions........................................................... 86 Replacing the mast/straddle legs.......................................... 86 Dismantle the mast/straddle legs from the chassis..................... 86 Mount the mast/straddle legs on the chassis........................... 89 Dismantling the mast...................................................... 92 General............................................................... 92 Adjusting the lateral inclination in top position..................... 92 Adjusting the play in the mast........................................ 93 Replacement, DTFV mast................................................ 94 Replacement, TFV mast................................................. 96 Replacement, TV mast.................................................. 97 Replacement, T mast................................................... 98 Lift chains............................................................... 99 Replacement........................................................... 99 Re-fitting the chains................................................. 99 Check................................................................. 99 Forks.....................................................................101 Adjusting the lowest height on forged forks...........................101 Adjusting the lowest height on welded forks...........................101 Fork test.............................................................101 Fork carriage, general....................................................104 Adjusting the fork carriage...........................................104 Dismantling the fork carriage.........................................104 Fork carriage, telescopic forks, TF.......................................105 Dismantling the fork carriage TF......................................105 Assembling the fork carriage TF.......................................108 Inspection after assembling the fork carriage TF......................109 Adjusting the overload clutch (TF)....................................110 Replacing the fork drive motor (TF)...................................111 Replacing the coupling between fork drive motor and gearbox (TF)......111 Replacing the cabling, fork drive motor (TF)..........................112 Straddle lift.............................................................113 Adjusting the straddle lift...........................................113 Dismantling and assembling of straddle lift...........................114 Side stabilisers..........................................................115 Checking the side stabiliser..........................................115 Adjusting the length of side stabilisers..............................115 Diagnosis and trouble shooting................................................116 Trouble shooting chart....................................................116 07....................................................................................117 7 Steering........................................................................117 Design and function...........................................................119 General...................................................................119 Steering..................................................................119 Regulator, steering servo motor...........................................120 Repair instructions...........................................................121 Steering wheel, step motor sensor.........................................121 Steering servo motor with gearbox.........................................121 Replacing the steering servo sensor.......................................122 Diagnosis and trouble shooting................................................123 08....................................................................................125 8 Hydraulic system................................................................125 Hydraulic diagram, Proportional valve 104005 (-2008w45).......................134 Hydraulic diagram, ALL 104913.................................................138 Hydraulic diagram, Manual valve 104014 (-2008w45).............................130 Design and function...........................................................127 General...................................................................127 Lift..................................................................127 Lower.................................................................127 Hose rupture valve........................................................128 Lowering brake valve......................................................128 Mechanical control valve..................................................128 General...............................................................128 Lifting function......................................................128 Lowering function.....................................................128 Electric control valve....................................................128 General...............................................................128 Lifting function......................................................129 Lowering function.....................................................129 Lowering brake function...............................................129 Hydraulic diagram.........................................................129 Repair instructions...........................................................140 Hydraulic system..........................................................140 General rules.........................................................140 Installation..........................................................140 Connections...........................................................141 Start up..............................................................141 Hydraulic oil, changing/draining..........................................142 Properties of the hydraulic oil.......................................142 Requisite equipment...................................................142 Procedure.............................................................143 Air filter, replacing.....................................................144 Oil filter insert, replacement............................................145 Checking the hydraulic oil level..........................................146 Lowering brake valve......................................................147 Dismantling and assembling............................................147 Hose rupture valve........................................................149 Dismantling and assembling............................................149 Control valve.............................................................151 General instructions when working with control valve..................151 Manually operated hydraulic valve, dismantling and assembling.........152 Electrically operated control valve, dismantling and assembling.......153 Checking the lowering speed...........................................154 Adjusting the regulator, electric valve...............................154 Adjusting the lowering speed valve in the electric hydraulic valve....154 Adjusting the working pressure........................................155 Emergency lowering valve..............................................155 Hydraulic pump motor......................................................156 Dismantling the hydraulic pump motor..................................156 Hydraulic pump motor ALL..................................................157 When should the brushes be replaced?..................................157 Replacing the brushes.................................................157 Tips to prolong the service-life of the motor.........................159 Stabiliser cylinders......................................................160 Dismantling and assembling the stabiliser cylinders...................160 Dismantling and assembling, gaskets...................................160 Installation instruction for pipe couplings...............................161 Diagnosis and trouble shooting................................................164 Symptom and Action........................................................164 Hydraulic diagram, Manual valve 104014 (2008w46-).....................132 Hydraulic diagram, Proportional valve 104005 (2008w46-)...............136 09....................................................................................167 9 Lift cylinders..................................................................167 Design and function...........................................................169 Introduction..............................................................169 Repair instructions...........................................................170 General...................................................................170 Free-lift cylinder TFV / DTFV.............................................171 Lift cylinder TV/TFV/DTFV.................................................173 Lift cylinder T...........................................................176 10....................................................................................179 10 Electrical system..............................................................179 General.......................................................................181 Safety procedures.........................................................181 Safety check..............................................................182 Operation, Hand terminal..................................................184 Design and function...........................................................187 General functional description, regulators................................187 Multi Function Display Indicator (MDI)....................................191 Drive motor regulator, AC1................................................193 Steering servoregulator, EPS-AC...........................................208 Wiring diagram............................................................215 Repair instructions...........................................................216 Calibration, Speed controller.............................................216 Calibration, Lifting/Lowering control.....................................219 Save parameters in the Hand terminal memory...............................222 Download parameters from the Hand terminal................................224 Checking error codes......................................................226 Replacing drive regulator/steering servo regulator........................228 Replacing MDI.............................................................228 Replacing the steering servo sensor.......................................229 Diagnosis and trouble shooting................................................230 Safety....................................................................230 Tools for trouble shooting................................................230 Practical trouble shooting................................................232 Error codes...............................................................234 11....................................................................................243 11 Brake and speed system.........................................................243 Design and function...........................................................245 Electric brake............................................................245 Repair instructions...........................................................246 Electric brake............................................................246 Speed controller..........................................................250
ATLET TRUCK A-ERGO A-ERGO TF WORKSHOP SERVICE MANUAL – PDF DOWNLOAD:
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PLEASE NOTE:
- 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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