ATLET Truck U UNS UNN UHSUFS URF USS AC Power Plus Service Manual – PDF DOWNLOAD

Description

ATLET Truck U UNS UNN UHSUFS URF USS AC Power Plus Service Manual – PDF DOWNLOAD

DESCRIPTION:

ATLET Truck U UNS UNN UHSUFS URF USS AC Power Plus Service Manual – PDF DOWNLOAD

Machine: U AC Power Plus
Manual nr: 005954

TABLE OF CONTENTS:

ATLET Truck U UNS UNN UHSUFS URF USS AC Power Plus Service Manual – PDF DOWNLOAD

01..............................................................................................................  1
	1 General information and technical data....................................................................  1
		1.1 Introduction........................................................................................  5
			1.1.1 Service manual................................................................................  5
			1.1.2 The trucks....................................................................................  5
		1.2 Manual structure....................................................................................  6
			1.2.1 Symbol key....................................................................................  6
			1.2.2 History.......................................................................................  7
		1.3 Safety..............................................................................................  8
			1.3.1 Lifting points................................................................................  8
			1.3.2 Safety instructions...........................................................................  9
			1.3.3 Environmentally hazardous waste - environment.................................................  9
			1.3.4 Handling...................................................................................... 10
			1.3.5 Trouble shooting.............................................................................. 10
		1.4 Designations........................................................................................ 11
			1.4.1 Truck types................................................................................... 11
		1.5 Dimension........................................................................................... 17
			1.5.1 Dimension description UNS, UHS................................................................ 17
			1.5.2 Dimension description UFS..................................................................... 18
			1.5.3 Dimension description USS..................................................................... 19
			1.5.4 Dimension description URF..................................................................... 20
		1.6 Component specification............................................................................. 21
			1.6.1 Drive motor................................................................................... 21
			1.6.2 Electric brake................................................................................ 21
			1.6.3 Gearbox....................................................................................... 21
			1.6.4 Hydraulic unit................................................................................ 22
			1.6.5 Control system for motor...................................................................... 22
			1.6.6 Battery....................................................................................... 23
			1.6.7 Servo motor................................................................................... 23
			1.6.8 Steering servo unit “fly by wire”............................................................. 23
			1.6.9 Steering servo unit EPS 2001.................................................................. 23
		1.7 Torque.............................................................................................. 24
			1.7.1 Conversion table torque....................................................................... 24
			1.7.2 Bolt types and tensile grades................................................................. 25
		1.8 Lubrication......................................................................................... 27
			1.8.1 Lubrication chart UNS, UNN, UHS, USS, UFS..................................................... 27
			1.8.2 Lubrication chart URF......................................................................... 28
			1.8.3 Symbol key lubrication chart.................................................................. 29
		1.9 Recommended oil and grease types.................................................................... 30
			1.9.1 Recommended changing.......................................................................... 30
		1.10 Code explanations.................................................................................. 31
			1.10.1 Machine colours according to NCS............................................................. 31
			1.10.2 Colour codes for Atlet's wiring diagrams..................................................... 31
			1.10.3 Designations for electrical components....................................................... 32
			1.10.4 Units........................................................................................ 33
02.............................................................................................................. 35
	2 Special tools............................................................................................. 35
		2.1 List of tools....................................................................................... 37
03.............................................................................................................. 39
	3 Service................................................................................................... 39
		3.1 Introduction........................................................................................ 41
			3.1.1 Service intervals............................................................................. 41
		3.2 Service inspection.................................................................................. 42
			3.2.1 General....................................................................................... 42
			3.2.2 Check list.................................................................................... 43
		3.3 Code explanation.................................................................................... 48
04.............................................................................................................. 53
	4 Chassis................................................................................................... 53
		4.1 Introduction........................................................................................ 55
		4.2 Chassis, plates..................................................................................... 56
			4.2.1 Dismantling, assembling the overhead guard.................................................... 56
			4.2.2 Dismantling, assembling the overhead guard stanchion.......................................... 56
		4.3 Chassis, machine housing components, Seefigure4.2................................................. 58
			4.3.1 Dismantling, assembling the load wheel........................................................ 58
			4.3.2 Adjusting the door............................................................................ 58
			4.3.3 Battery lock, battery type R.................................................................. 60
		4.4 Panels.............................................................................................. 61
			4.4.1 Dismantling, assembling the panels............................................................ 61
		4.5 Adjustable arm rest U*S............................................................................. 62
			4.5.1 Dismantling, assembling the arm rest.......................................................... 62
		4.6 Driver seat U*S..................................................................................... 63
			4.6.1 Adjusting..................................................................................... 63
05.............................................................................................................. 65
	5 Drive unit................................................................................................ 65
		5.1 Introduction........................................................................................ 67
		5.2 Dismantling, assembling the dive unit............................................................... 68
		5.3 Drive motor, general instructions................................................................... 69
			5.3.1 Storage of machines and motors................................................................ 69
			5.3.2 First service................................................................................. 69
			5.3.3 Preventive maintenance........................................................................ 69
			5.3.4 Dismantling, assembling the motor............................................................. 69
			5.3.5 Replacing the motor bearings.................................................................. 71
			5.3.6 Replacing the bearing housing................................................................. 72
		5.4 Reconditioning the motor............................................................................ 73
			5.4.1 Motor bearings................................................................................ 73
			5.4.2 Tightening of nuts on the pinion on the motor shaft........................................... 73
			5.4.3 Stator housing................................................................................ 73
		5.4.4 Assembly.......................................................................................... 73
		5.5 Gearbox............................................................................................. 74
			5.5.1 First service................................................................................. 74
			5.5.2 Preventive maintenance........................................................................ 74
			5.5.3 Replacing the gearbox......................................................................... 74
		5.6 Drive shaft and drive wheel......................................................................... 76
			5.6.1 Replacing the drive shaft seal................................................................ 76
			5.6.2 Replacing the drive wheel..................................................................... 77
			5.6.3 Trouble shooting chart........................................................................ 78
06.............................................................................................................. 81
	6 Mast...................................................................................................... 81
		6.1 Mast................................................................................................ 85
			6.1.1 Dismantling of masts 141, 200................................................................. 85
			6.1.2 Dismantling of masts 140, 160, 161............................................................ 87
			6.1.3 Adjusting the brass lugs 141, 200............................................................. 88
			6.1.4 Adjusting the mast, top 141, 200.............................................................. 88
			6.1.5 Adjusting the masts 140, 160, 161............................................................. 89
			6.1.6 Mast damper (2003w03=>)....................................................................... 92
		6.2 Reach carriage...................................................................................... 94
			6.2.1 Dismantling the reach carriage 141, 200....................................................... 94
			6.2.2 Dismantling of reach carriage 140, 160, 161................................................... 94
			6.2.3 Adjusting the reach carriages 141, 200........................................................ 94
			6.2.4 Adjusting the reach carriages 140, 160, 161................................................... 96
		6.3 Fork carriage....................................................................................... 97
			6.3.1 Adjusting the fork carriage, 141, 200......................................................... 97
			6.3.2 Adjusting the fork carriages 140, 160, 161.................................................... 98
			6.3.3 Dismantling, assembling the fork carriage..................................................... 98
			6.3.4 Fork test..................................................................................... 99
		6.4 Fork side shift unit................................................................................101
			6.4.1 Trouble shooting..............................................................................102
		6.5 Lift cylinders......................................................................................103
			6.5.1 Adjusting the cylinder attachment in the mast.................................................103
		6.6 Lift chains.........................................................................................104
			6.6.1 Adjusting the lift chains.....................................................................104
			6.6.2 Checking the lift chains......................................................................104
			6.6.3 Regular maintenance...........................................................................105
			6.6.4 Re-fitting the chains.........................................................................106
		6.7 Trouble shooting....................................................................................107
			6.7.1 Trouble shooting chart 141, 200...............................................................107
			6.7.2 Trouble shooting charts 140, 160, 161.........................................................107
		6.8 Three-way-stack unit type 134 URF...................................................................108
			6.8.1 Safety instructions...........................................................................108
			6.8.2 General description...........................................................................109
			6.8.3 Installation instructions.....................................................................111
			6.8.4 Torque [Nm]...................................................................................112
			6.8.5 Pipe and hose connection......................................................................113
			6.8.6 Function test.................................................................................113
			6.8.7 Hydraulic lines and connections...............................................................114
			6.8.8 Adjusting.....................................................................................116
			6.8.9 Fork holder...................................................................................117
			6.8.10 Rotation cylinders...........................................................................117
			6.8.11 Boom.........................................................................................117
			6.8.12 Cam adjustment...............................................................................117
			6.8.13 Pinion drive axle............................................................................119
			6.8.14 Thrust rollers...............................................................................119
			6.8.15 Hydraulic motor..............................................................................120
			6.8.16 Working conditions and dismantling of motors.................................................120
			6.8.17 Inspection list..............................................................................121
07..............................................................................................................123
	7 Steering..................................................................................................123
		7.1 Introduction........................................................................................125
			7.1.1 Chapter structure.............................................................................125
			7.1.2 Comprehensive description - fly by wire steering..............................................125
			7.1.3 Comprehensive description - EPS 2001 steering.................................................126
		7.2 Steering servo motor................................................................................128
			7.2.1 Adjustment of steering servo system - fly by wire.............................................128
			7.2.2 Dismantling the steering servo motor..........................................................128
		7.3 Settings, adjustments and tests.....................................................................129
			7.3.1 Controller, functions - fly by wire...........................................................129
			7.3.2 Setting of controller - fly by wire...........................................................129
			7.3.3 Controller factory settings - fly by wire.....................................................131
			7.3.4 Operation test of steering servo system - fly by wire.........................................131
			7.3.5 Mechanical adjustment to the steering sensors - EPS 2001......................................132
			7.3.6 Operation test of the steering steering sensors - EPS 2001....................................132
			7.3.7 Calibration of the sensor system - EPS 2001...................................................132
			7.3.8 Setting of steering wheel indicator - EPS 2001................................................132
			7.3.9 Setting of straight steering - URF EPS 2001...................................................133
			7.3.10 Driver setting for steering sensitivity - EPS 2001...........................................134
		7.4 Options.............................................................................................135
			7.4.1 Limited or continuous steering - EPS 2001.....................................................135
			7.4.2 Mini-wheel or midi-wheel - EPS 2001...........................................................135
		7.5 Diagnostics and trouble shooting....................................................................136
			7.5.1 Fly by Wire...................................................................................136
			7.5.2 EPS 2001......................................................................................137
08..............................................................................................................139
	8 Hydraulic system..........................................................................................139
		8.1 Introduction........................................................................................143
			8.1.1 Description...................................................................................143
		8.2 Hydraulic system general regulations................................................................145
			8.2.1 Installation..................................................................................145
			8.2.2 Connections...................................................................................145
			8.2.3 Start up......................................................................................146
			8.2.4 Installation instruction for pipe couplings...................................................146
		8.3 Hydraulic filter....................................................................................150
			8.3.1 Replace.......................................................................................150
		8.4 Pump motor..........................................................................................151
			8.4.1 Dismantling...................................................................................151
			8.4.2 Replacing the motor bearings..................................................................152
			8.4.3 Replacing the bearing housing.................................................................153
			8.4.4 Assembly......................................................................................153
		8.5 Suction hose........................................................................................154
			8.5.1 Replace.......................................................................................154
		8.6 Tank................................................................................................156
			8.6.1 Draining......................................................................................156
		8.7 Cylinders...........................................................................................157
			8.7.1 Dismantling the reach cylinder................................................................157
			8.7.2 Dismantling, assembling the reach cylinder....................................................158
			8.7.3 Bleeding the reach cylinder...................................................................159
			8.7.4 Dismantling the tilt cylinder from the truck..................................................160
			8.7.5 Dismantling, assembling the tilt cylinder.....................................................160
		8.8 Valves..............................................................................................161
			8.8.1 Operation of control valve....................................................................161
			8.8.2 Adjusting the working pressure................................................................162
			8.8.3 Emergency lowering valve......................................................................162
			8.8.4 Troubleshooting control valve.................................................................163
			8.8.5 Setting the hose rupture valve................................................................164
		8.9 Hydraulic control...................................................................................165
			8.9.1 Calibration...................................................................................165
		8.10 Hydraulic diagram..................................................................................166
			8.10.1 Revision list................................................................................166
09..............................................................................................................175
	9 Lift cylinders............................................................................................175
		9.1 Free lift cylinder..................................................................................177
			9.1.1 Dismantling...................................................................................177
			9.1.2 Dismantling...................................................................................178
			9.1.3 Draining, bleeding............................................................................179
		9.2 Outer cylinder......................................................................................180
			9.2.1 Dismantling...................................................................................180
			9.2.2 Dismantling...................................................................................181
		9.3 Free lift cylinder URF..............................................................................182
			9.3.1 Dismantling...................................................................................182
			9.3.2 Bleeding......................................................................................187
		9.4 Free lift cylinder URF, older design................................................................188
			9.4.1 Dismantling...................................................................................188
		9.5 Free lift cylinder URF, newer design................................................................192
			9.5.1 Dismantling...................................................................................192
10..............................................................................................................195
	10 Electrical system........................................................................................195
		10.1 Introduction.......................................................................................201
			10.1.1 Component description........................................................................201
			10.1.2 Safety.......................................................................................201
		10.2 Battery............................................................................................203
			10.2.1 Replace......................................................................................203
			10.2.2 Capacity measurement.........................................................................204
			10.2.3 Battery parameters from version 3.00.........................................................206
		10.3 Chassis............................................................................................207
			10.3.1 Checking the ATC - chassis connection........................................................207
			10.3.2 Potential measurement........................................................................207
			10.3.3 Optical aisle sensor, rail guidance..........................................................208
			10.3.4 Caster wheel rotation lock, UFS..............................................................209
		10.4 Connectors in cold storage rooms...................................................................211
			10.4.1 Greasing.....................................................................................211
		10.5 Drive and pump regulator (2005w04-)................................................................212
			10.5.1 Dismantling, assembling......................................................................212
			10.5.2 Designation..................................................................................212
			10.5.3 General on control of the AC motors..........................................................212
			10.5.4 Connections..................................................................................212
			10.5.5 Cable connections............................................................................213
			10.5.6 Power cables.................................................................................213
		10.6 Insulation resistance..............................................................................214
			10.6.1 Routine test.................................................................................214
		10.7 Temperature measurement............................................................................215
			10.7.1 Trouble shooting - hydraulic functions channels 3, 4 and 5...................................216
		10.8 Magnet switch for the reach stop...................................................................217
			10.8.1 Reach stop...................................................................................217
			10.8.2 Reach stop damping (2005w04÷) (trucks with S3)...............................................218
		10.9 Fuses..............................................................................................220
			10.9.1 Standard.....................................................................................220
			10.9.2 Extra accessories............................................................................220
		10.10 Horn..............................................................................................222
			10.10.1 Connection..................................................................................222
		10.11 Atlet's truck computer ATC........................................................................223
			10.11.1 Component and interface description.........................................................223
			10.11.2 Handling....................................................................................224
			10.11.3 Service functions...........................................................................225
			10.11.4 Change passwords............................................................................225
			10.11.5 Calibration and control of the hydraulic levers.............................................226
			10.11.6 Running time functions......................................................................226
			10.11.7 Printing of statistics......................................................................226
			10.11.8 Collision sensor............................................................................226
			10.11.9 ATC connector...............................................................................226
			10.11.10 Checking the inputs and outputs............................................................227
			10.11.11 Digital inputs.............................................................................227
			10.11.12 Digital outputs “XC1-XC11”.................................................................229
			10.11.13 Digital outputs B+ supply..................................................................230
			10.11.14 Digital outputs 12 V supply................................................................230
			10.11.15 Digital outputs B+ supply..................................................................231
			10.11.16 Valve parameters...........................................................................231
			10.11.17 Performance parameters.....................................................................232
		10.12 Error codes.......................................................................................237
			10.12.1 General.....................................................................................237
			10.12.2 Error code description......................................................................237
		10.13 Warnings..........................................................................................251
			10.13.1 Description.................................................................................251
		10.14 Menu tree ATC.....................................................................................252
			10.14.1 Error log...................................................................................252
			10.14.2 Subinfo.....................................................................................252
			10.14.3 General instructions with all types of faults on trucks in combination with power outage....252
		10.15 Trouble shooting - operational disturbance........................................................254
			10.15.1 Truck and ATC...............................................................................254
			10.15.2 Battery.....................................................................................255
			10.15.3 Main contactor..............................................................................255
			10.15.4 Fuse........................................................................................256
			10.15.5 The drive regulator status indicator........................................................257
			10.15.6 Traction motor..............................................................................258
			10.15.7 Pump motor..................................................................................262
			10.15.8 Pump regulator status indicator.............................................................265
			10.15.9 Steering system - EPS 2001..................................................................266
			10.15.10 The drive function.........................................................................268
			10.15.11 Forks......................................................................................269
			10.15.12 Automatic driving of the drive unit - UFS..................................................275
			10.15.13 Rotating wheel indication - UFS............................................................275
			10.15.14 Low temp drive/Low temp hydraul............................................................276
			10.15.15 High/Low voltage - EPS 2001................................................................276
			10.15.16 High temp Steering/Overheated steer - EPS 2001.............................................277
		10.16 Trouble shooting - error messages.................................................................278
			10.16.1 E05, E06, E07, Electric servo - fly by wire.................................................278
			10.16.2 CAN.........................................................................................279
			10.16.3 E97, E98. Drive system stopped/ Hydraulics stopped..........................................280
			10.16.4 E100, E101. Drive system abnormal/ Hydraulics abnormal......................................284
			10.16.5 E102, E103, E107 Servo stopped/Servo abnormal -EPS 2001.....................................286
			10.16.6 E105, Drive system..........................................................................290
			10.16.7 E106, Pump system...........................................................................292
		10.17 Trouble shooting table - battery..................................................................295
			10.17.1 Battery stop................................................................................295
		10.18 Wiring diagram....................................................................................296
		10.19 Appendix 1, Menu tree.............................................................................297
11..............................................................................................................340
	11 Speed control and brake systems..........................................................................340
		11.1 Speed control, U*S.................................................................................342
			11.1.1 Dismantling the speed and brake controls, U*S................................................342
			11.1.2 Inspection and adjustment of the speed control...............................................342
			11.1.3 Gill sensor..................................................................................344
			11.1.4 Calibration of speed controller (Gill sensor)................................................344
			11.1.5 Calibration of speed controller (SLOAN)......................................................346
		11.2 Brake pedal........................................................................................348
			11.2.1 Adjusting and inspecting the brake pedal.....................................................349
		11.3 Left-foot switch, U*S..............................................................................351
			11.3.1 Dismantling, assembling the left-foot switch.................................................351
			11.3.2 Adjusting the left-foot switch...............................................................352
			11.3.3 Preventive maintenance.......................................................................352
		11.4 Electric brake.....................................................................................353
			11.4.1 Electric brake, 1 disc (–2003w01)............................................................353
			11.4.2 Electrical brake, new version (2003w02–).....................................................354
		11.5 Trouble shooting...................................................................................357
			11.5.1 The brakes do not release....................................................................357
12..............................................................................................................358
	12 Extra accessories........................................................................................358
		12.1 Level selector.....................................................................................362
			12.1.1 Setting the switch level system..............................................................363
			12.1.2 Height preselection..........................................................................363
			12.1.3 Operating height preselection................................................................363
			12.1.4 Pulse height preset..........................................................................364
			12.1.5 Operation....................................................................................365
			12.1.6 Checking settings............................................................................366
			12.1.7 Example of use...............................................................................366
		12.2 Height measurement instrument......................................................................367
			12.2.1 General......................................................................................367
			12.2.2 Technology...................................................................................367
			12.2.3 Settings.....................................................................................367
			12.2.4 Programming..................................................................................367
			12.2.5 Setting the offset value.....................................................................368
			12.2.6 Protecting the preset value..................................................................368
			12.2.7 Setting COEFF................................................................................368
			12.2.8 Setting dECPt................................................................................368
			12.2.9 Final test...................................................................................368
			12.2.10 Sensor......................................................................................369
			12.2.11 Adjusting the sensor........................................................................369
			12.2.12 Height indication on the display............................................................369
		12.3 Cabin..............................................................................................369
		12.4 Ergologic..........................................................................................372
			12.4.1 Electric calibration.........................................................................372
			12.4.2 Mechanical adjustment of the lifting/lowering potentiometer..................................373
		12.5 Semi-automatic tilt centring.......................................................................373
		12.6 Semi-automatic side-shift centring.................................................................374
		12.7 Stability Support System, S3.......................................................................374
			12.7.1 Identification...............................................................................374
			12.7.2 Functionality................................................................................375
			12.7.3 Drive Speed..................................................................................376
			12.7.4 Hydraulic functions..........................................................................377
			12.7.5 Technical description........................................................................378
		12.8 S3 option 2 (S3-2) Weight indication...............................................................379
			12.8.1 Functionality................................................................................379
			12.8.2 Technical description........................................................................379
			12.8.3 Calibration..................................................................................379
		12.9 Truck Remote ACcess, TRAC..........................................................................382

ATLET TRUCK U UNS UNN UHSUFS URF USS AC POWER PLUS SERVICE MANUAL – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

S.V