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Atlet Truck P Series PPC PPD PPL PPF & PPS Service Manual – PDF DOWNLOAD
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Atlet Truck P Series PPC PPD PPL PPF & PPS Service Manual – PDF DOWNLOAD
Machine: PP*
Manual No: 119036
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Description
Atlet Truck P Series PPC PPD PPL PPF & PPS Service Manual – PDF DOWNLOAD
DESCRIPTION:
Atlet Truck P Series PPC PPD PPL PPF & PPS Service Manual – PDF DOWNLOAD
Machine: PP*
Manual No: 119036
General:
This manual describes the service procedure for ATLET Low Picking Truck PP*. Use the manual for quick and correct service of respective truck models. You may find inconsistencies in the manual compared to the models supplied due to optional designs, upgrades and the like.
Scope of P series:
This manual covers the Low Picking Trucks PPC, PPD, PPL, PPF and PPS.
How to use the manual :
Structure :
- The manual is arranged according to the same principles as ATLET’s spare part catalogues, with the truck divided into one subsystem per Tab.
- Tabs 1-3 in this manual contain comprehensive information regarding technical data, service instructions and tools.
- Tabs 4-12 in the manual contain information limited to a specific part of the truck dealing with the mechanical operation of the various components, for example, Masts (Tab 6) and Hydraulic System (Tab 8).
- The software is described under Tab 10.
- The main principle for extra accessories is to place them under the relevant Tab. Otherwise they are placed under Tab 12 “Miscellaneous”. For this reason Tab 12 is not always included in the Service Manual.
- For specific problems and 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 always to 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 regulations should be observed.
• Always lift the drive wheel free from the floor during service work to prevent the vehicle from moving.
• Remove the battery plug before working on the electrical system. The battery plug may only be connected while troubleshooting, and when the greatest of care is exercised, (with the truck raised).
• In order to avoid crushing injuries, always remove the battery plug when working on or around masts and hydraulic units. The mast or hydraulic unit may be actuated due to an electrical fault or a mistake while working.
TABLE OF CONTENTS:
Atlet Truck P Series PPC PPD PPL PPF & PPS Service Manual – PDF DOWNLOAD
01..................................................................................... 1 1 General information and technical data........................................... 1 Service manual scope........................................................... 3 General.................................................................... 3 Scope of P series.......................................................... 3 How to use the manual.......................................................... 4 Structure.................................................................. 4 Symbol key................................................................. 4 Safety instructions............................................................ 5 General.................................................................... 5 Lifting the truck.......................................................... 6 Inspection/Preparations................................................ 6 Permitted lifting points............................................... 6 Welding of truck........................................................... 8 Atlet cares about the environment.......................................... 8 Environmental impact....................................................... 8 Waste...................................................................... 8 Preparations................................................................... 9 Service.................................................................... 9 Troubleshooting............................................................ 9 Data PP*....................................................................... 10 Designations............................................................... 10 Truck designation...................................................... 10 Type designation....................................................... 11 Dimensions and weights..................................................... 14 Machine specification.................................................. 15 Component specifications................................................... 16 Recommended incidental material................................................ 18 Oil and grease............................................................. 18 Standards and abbreviations.................................................... 19 Screws..................................................................... 19 Tightening torque, bolts and nuts...................................... 19 Bolt types and tensile grades.......................................... 19 Tightening torque for hydraulic connections................................ 21 Conversion tables.......................................................... 21 Standard abbreviations..................................................... 22 Colour of truck............................................................ 22 Colour codes cabling....................................................... 23 Designations............................................................... 23 02..................................................................................... 25 2 Special tools.................................................................... 25 Special tools PP*.............................................................. 27 Introduction............................................................... 27 List of tools.............................................................. 27 Cleaning fluid......................................................... 27 Chain spray............................................................ 27 Crimping tool.......................................................... 27 Hand terminal/communications cable..................................... 28 03..................................................................................... 29 3 Service.......................................................................... 29 Routine maintenance............................................................ 31 Introduction............................................................... 31 Safety..................................................................... 31 Recommendations............................................................ 31 Daily maintenance.......................................................... 32 This is the responsibility of the truck driver (before each shift)..... 32 This is the responsibility of the truck driver (after each shift)...... 32 Weekly service (30 operating hours)........................................ 33 Responsibility: Truck driver........................................... 33 Initial service............................................................ 33 Main service............................................................... 33 Extra service inspections.................................................. 34 Check-list, service inspection............................................. 35 Code explanation........................................................... 39 Lubrication chart.......................................................... 44 PP*.................................................................... 44 Symbol explanations, lubrication chart................................. 46 Specific instructions.......................................................... 47 Traction motor............................................................. 47 Preventive maintenance................................................. 47 Gearbox.................................................................... 47 Initial service........................................................ 47 Preventive maintenance................................................. 47 Lift chains and forks...................................................... 48 Check.................................................................. 48 Scissor lift (PPSF/PPSC)............................................... 49 Hydraulic oil.................................................................. 50 Initial service............................................................ 50 Intervals.................................................................. 50 Emergency stop............................................................. 50 Recommended replacement.................................................... 51 Storage of trucks and motors............................................... 51 04..................................................................................... 53 4 Chassis.......................................................................... 53 Design and function............................................................ 55 Scope...................................................................... 55 Gas spring in tiller arm and picking shelf............................. 55 Machine housing............................................................ 56 Dismantling the driver platform............................................ 57 a) Fixed floor......................................................... 57 b) Driver lift......................................................... 58 Assembling and adjusting the driver lift................................... 60 Assembly............................................................. 60 Adjusting.............................................................. 60 Repair instructions............................................................ 63 Covers and panels.......................................................... 63 Dismantling the panels................................................. 63 Replacement of footswitches............................................ 64 Caster wheel............................................................... 64 Replacing the caster wheel/bearing..................................... 65 Dismantling............................................................ 65 Assembly............................................................... 65 Battery.................................................................... 66 Battery replacement.................................................... 66 Replacing the battery rollers.......................................... 66 05..................................................................................... 67 5 Drive line....................................................................... 67 Design and function............................................................ 69 Introduction............................................................... 69 Traction motor............................................................. 69 Gearbox.................................................................... 69 Pivot...................................................................... 70 Repair instructions........................................................ 71 Dismantling/assembling the pivot........................................... 71 Adjusting the pivot........................................................ 72 PPL/PPD (low-lifters).................................................. 72 PPF/PPC (fork lift), and PPS (scissor lift)............................ 74 Service, pivot............................................................. 74 Lubrication............................................................ 74 Replacement of springs................................................. 75 Traction motor............................................................. 75 Dismantling, assembling the traction motor............................. 75 Storage, traction motor................................................ 76 Gearbox.................................................................... 76 Dismantling, assembling the gearbox.................................... 76 Motor bracket.......................................................... 77 Replacement of studs................................................... 77 Service and mounting of the gearbox lower axle seal.................... 77 Guide bearing.......................................................... 77 Gear ring and pinion................................................... 77 Check of oil level and topping up the oil.............................. 77 Oil change............................................................. 77 Dismantling, mounting the servo motor.................................. 79 Drive wheel................................................................ 79 Replacing the drive wheel.............................................. 79 Diagnostics and troubleshooting................................................ 81 Troubleshooting chart...................................................... 81 06..................................................................................... 83 6 Mast............................................................................. 83 Design and function............................................................ 85 Lift system................................................................ 85 Repair instructions............................................................ 86 Fork carriage.............................................................. 86 Dismantling fork carriage, lifting fork (PPL/ PPD)..................... 86 Alternative 1.......................................................... 86 Alternative 2.......................................................... 87 Dismantling the fork carriage, forklift (PPC/PPF)...................... 87 Dismantling the pallet truck, scissor lift (PPSF/PPSC)................. 88 Adjusting the fork carriage................................................ 90 Low lifting (PPL/PPD).................................................. 90 Forklift (PPC/PPF)..................................................... 91 Adjustment and inspection of wear, scissor lift (PPSF/PPSC)............ 92 Dismantling and assembling the masts....................................... 93 General................................................................ 93 Adjusting the mast..................................................... 93 Bogie...................................................................... 93 Low-lifters (PPL/PPD).................................................. 93 Replacing worn and damaged parts:...................................... 93 Dismantling............................................................ 93 Assembly............................................................... 94 Forklift (PPC/PPF)..................................................... 95 Replacing worn and damaged parts:...................................... 95 Dismantling............................................................ 95 Lift chains................................................................ 95 Check (PPF/PPC/PPSF/PPSC).............................................. 95 Diagnostics and troubleshooting................................................ 97 Troubleshooting chart...................................................... 97 07..................................................................................... 99 7 Steering......................................................................... 99 Design and function............................................................101 General....................................................................101 Mechanical steering....................................................101 Electric servo steering................................................102 Repair instructions............................................................103 Mechanical steering........................................................103 Adjusting the tiller arm, drive wheel and straight steering sensor.....103 Adjusting the steering chain...........................................104 Replacement of toggle link bearings....................................105 Tiller arm head, mechanical steering (-2007w27)............................106 Replacement............................................................106 Tiller arm head (2007w28-).................................................107 Dismantling the tiller arm head........................................107 Dismantling buttons lift/lower.........................................108 Dismantling the speed controller.......................................108 Assembly of main cable.................................................109 Tiller arm (2007w28-)......................................................111 Dismantling the gas spring.............................................111 Tiller arm head, servo steering............................................112 Removing the top cover.................................................112 Mounting of moving parts for throttle setting..........................113 Replacing the potentiometer............................................113 Replacing the torsion springs..........................................113 Replacing the gas dashpot..............................................113 Cleaning...................................................................113 08.....................................................................................115 8 Hydraulic system.................................................................115 Design and function............................................................117 General....................................................................117 Lifting................................................................117 Functional description.................................................117 Changing the hydraulic oil.............................................117 Lowering...............................................................118 Electric solenoid valve....................................................118 General................................................................118 Lifting function.......................................................118 Lowering function......................................................118 Hydraulic diagram PPL......................................................120 Repair instructions............................................................128 Hydraulic system...........................................................128 General rules..........................................................128 Installation...........................................................128 Connections............................................................129 Start up...............................................................129 Hydraulic oil, changing/draining...........................................130 Requisite equipment....................................................130 Procedure..............................................................130 Air filter.............................................................130 Hydraulic oil quality..................................................131 Motor, hydraulic unit......................................................132 When should the brushes be replaced?...................................132 Replacement of brushes.................................................132 Tips for extending the service life of the motor.......................133 Solenoid valve.............................................................134 General instructions when working with solenoid valves.................134 Solenoid valve, dismantling and assembling.............................136 Installation instructions for pipe couplings...............................136 Diagnostics and troubleshooting................................................139 Symptoms and corrective actions............................................139 Hydraulic diagram..........................................................119 Hydraulic diagram PPF, PPSF................................................122 Hydraulic diagram PPD......................................................124 Hydraulic diagram PPC, PPSC................................................126 09.....................................................................................141 9 Lift cylinder....................................................................141 Design and function............................................................143 Introduction...............................................................143 Lift cylinder, fork carriage...............................................143 Low-lifters (PPL/ PPD) Dismantling and assembling......................143 Adjusting..............................................................143 Forklift (PPC/ PPF) Dismantling and assembling.........................144 Adjusting..............................................................144 Lift cylinder, driver lift.................................................144 Dismantling the lift cylinder..............................................146 Assembling the lift cylinder...............................................146 10.....................................................................................147 10 Electrical system...............................................................147 Design and function............................................................149 General....................................................................149 Component description..................................................149 Component and interface description....................................150 Repair instructions............................................................151 General....................................................................151 Safety procedures......................................................151 Abbreviations..........................................................152 Battery....................................................................152 Battery capacity.......................................................152 General operation..........................................................154 Function keyboard......................................................154 Menu tree - start-up and top level.....................................156 Connectors in cold storage rooms...........................................157 Greasing...............................................................157 Wiring diagram.........................................................157 Traction motor and valve controller........................................158 Specification of connectors for traction motor controller..............158 Valve controller HVC, contactors.......................................160 Electric Power Steering EPS-AC0........................................161 Specifications for connectors, electric power steering EPS-AC0.........162 Servo settings PP......................................................163 Steering sensitivity...................................................165 S3 - Stability Support System..........................................165 Driving speed..........................................................166 Insulation resistance......................................................166 Routine test...........................................................166 ATC main controller, operation.............................................167 Menus..................................................................167 Settings...............................................................168 Reset menu.............................................................168 Enter truck type.......................................................169 Monitor menu...........................................................169 Selection of options...................................................170 Calibrate accelerator..................................................170 Calibration of lifting and lowering controls (ATC T4 mk2, 2007w28-)....171 Registering new driver.................................................172 Change format to driver ID and access code.............................173 Change the access code for Local or Atlet service menu.................173 Log functions and hour meters..........................................174 Reading hour meter.....................................................174 Temperature log........................................................175 Error log..............................................................175 Reading the error log..................................................176 Clear the error log....................................................177 Performance parameters.................................................177 Steering...............................................................177 Speed control..........................................................177 Driver categories......................................................179 Set driver parameters..................................................179 Pin code...............................................................179 Safety checks..........................................................180 Speed restrictions.....................................................180 General functional description.........................................181 Truck modes............................................................181 Temperatures...........................................................182 Options................................................................183 ATC Logic..................................................................184 Download...................................................................187 Download of service data and logs to a PC..............................187 Download of “Truck Manager” statistical logs to a PC...................187 Connectors, ATC........................................................189 Digital inputs and outputs.............................................189 Cold resistance values.................................................192 Fuses......................................................................192 Diagnostics and troubleshooting................................................193 Truck Remote ACcess, TRAC..................................................193 Conditions.............................................................193 Use....................................................................193 Connection procedure...................................................193 Error codes................................................................194 Error code indication, ATC:............................................194 Error code indication, EPS:............................................198 Error code indication, TMC:............................................202 Error code indication HVC:.............................................207 Other troubleshooting..................................................209 Appendix 1, Summary menu tree..................................................219 11.....................................................................................250 11 Brake system and speed control..................................................250 Design and function............................................................252 Electric brake.............................................................252 Repair instructions............................................................253 Electric brake.............................................................253 Service................................................................253 Replacing brake disc...................................................253 Emergency release......................................................254
ATLET TRUCK P SERIES PPC PPD PPL PPF & PPS SERVICE MANUAL – PDF DOWNLOAD:
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