Atlet Truck P Series PLL PSL & PSD Service Manual – PDF DOWNLOAD
DESCRIPTION:
Atlet Truck P Series PLL PSL & PSD Service Manual – PDF DOWNLOAD
Machine: PLL PSD PSL
PLE
Manual No: 119000
General :
This manual describes the service procedures for ATLET low lifters and stackers. 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.
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. Master (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.
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.
TABLE OF CONTENTS:
Atlet Truck P Series PLL PSL & PSD 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 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 PLL, PSD................................................................. 10 Designations.............................................................. 10 Dimensions and weights.................................................... 14 Component specification................................................... 16 Recommended consumable materials.............................................. 17 Oil and grease............................................................ 17 Standards and abbreviations................................................... 18 Screws.................................................................... 18 Standard abbreviations.................................................... 20 Colour of the truck....................................................... 22 Colour codes, cabling..................................................... 22 Designations.............................................................. 23 02.................................................................................... 25 2 Special tools................................................................... 25 Special tools PLL/PSD/PSL..................................................... 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.......................................................... 41 Specific instructions......................................................... 45 Storage of machines and motors............................................ 45 Drive motor............................................................... 45 Gearbox................................................................... 45 Lift chains and forks..................................................... 47 Hydraulic oil............................................................. 48 Recommended replacement................................................... 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 Drive motor............................................................... 59 Gearbox................................................................... 59 Repair instructions........................................................... 60 Preparations.............................................................. 60 Drive motor............................................................... 60 Gearbox................................................................... 61 Drive wheel............................................................... 62 Diagnostics and trouble shooting.............................................. 64 Trouble shooting chart.................................................... 64 06.................................................................................... 67 6 Mast system..................................................................... 67 Design and function........................................................... 69 Mast system............................................................... 69 Fork carriage............................................................. 69 Repair instructions........................................................... 70 Replacing the mast........................................................ 70 Fork carriage, general.................................................... 71 Diagnostics and trouble shooting.............................................. 72 Trouble shooting chart.................................................... 72 07.................................................................................... 73 7 Steering........................................................................ 73 Design and function........................................................... 75 General................................................................... 75 Steering.................................................................. 75 Repair instructions........................................................... 76 Cleaning.................................................................. 76 Tiller head (-2007w27).................................................... 76 Tiller arm head (2007w28-)................................................ 77 Tiller arm (2007w28-)..................................................... 81 08.................................................................................... 83 8 Hydraulic system................................................................ 83 Design and function........................................................... 85 General................................................................... 85 Hose rupture valve........................................................ 85 Electric solenoid valve................................................... 85 Hydraulic diagram......................................................... 86 Repair instructions........................................................... 92 Hydraulic system.......................................................... 92 Hydraulic oil............................................................. 93 Motor, hydraulic unit..................................................... 94 Hose rupture valve........................................................ 96 Solenoid valve............................................................ 97 Installation instruction for pipe couplings............................... 98 Diagnostics and trouble shooting..............................................101 Symptom and Action........................................................101 09....................................................................................103 9 Lift cylinders..................................................................103 Design and function...........................................................105 Introduction..............................................................105 10....................................................................................107 10 Electrical system..............................................................107 Design and function...........................................................111 General...................................................................111 Repair instructions...........................................................114 General...................................................................114 Battery...................................................................115 General handling..........................................................117 Contactors in cold storage rooms..........................................120 Drive and valve controller................................................121 Insulation resistance.....................................................124 Main Controller Unit ATC, Handling........................................125 ATC Logic.................................................................143 Digital I/Os..............................................................147 Cold resistance values PLL/PSD............................................149 Fuses.....................................................................150 Diagnostics and trouble shooting..............................................151 Truck Remote ACcess, TRAC.................................................151 Appendix 1, Summary menu tree.................................................173 INTRODUCTION..............................................................175 Specification.................................................................175 Technical Data............................................................175 Block Diagram.............................................................176 Operation Elements........................................................176 Protection Features.......................................................177 Thermal Considerations....................................................178 Electrical Connections........................................................179 Control Connectors........................................................179 Encoder Connector (Incremental Speed Encoder).............................185 Power Connectors..........................................................185 Programming Setup - using Programming Console.................................186 The ZAPI - Programming Console............................................186 Overview on the Console functions when connected to an AC0 - MDI PRC -....189 Configuration of Options (SET OPTIONS)....................................190 Calibration (ADJUSTMENTS).................................................196 Parameter setting (PARAMETER CHANGE)......................................201 Measurement and Test Functions (TESTER)...................................204 Saving Settings (SAVE PARAM)..............................................208 Restoring settings (RESTORE PARAM)........................................210 Error Messages (ALARMS)...................................................212 Teach-In the Potentiometer Signal.........................................213 The Setting Process.......................................................214 Error messages................................................................216 Monitoring Functions of the Controller....................................216 Error-Code Table..........................................................217 Service Instructions..........................................................222 MDI AND MDI - PRC.............................................................223 MDI Connection............................................................223 Dimensions MDI IP64.......................................................224 MDI IP64 Connection.......................................................225 MDI-PRC...................................................................226 GLOSSARY......................................................................228 Adjustment Values.............................................................229 PLL Kordel................................................................229 PLL Sauer.................................................................235 PSD Kordel................................................................241 PSD Sauer.................................................................248 11....................................................................................286 11 Brake and drive system.........................................................286 Design and function...........................................................288 Electric brake............................................................288 Repair instructions...........................................................289 Electric brake............................................................289
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- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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