Atlet Truck UNS UNN UHS UFS URF USS AC Power Plus Service Manual – PDF DOWNLOAD
DESCRIPTION:
Atlet Truck UNS UNN UHS UFS URF USS AC Power Plus Service Manual – PDF DOWNLOAD
Maskin: U AC Power
Plus
Manual Nr: 005953
Inledning 1.1.1 Servicemanualen:
Manualen beskriver serviceförfarandet av ATLET skjutstativtruckar i U** AC Power Plus-serien. Använd manualen för snabb och rätt service av respektive truckmodell. Manualen beskriver modeller tillverkade från och med införandet av Mark 2 i slutet av 1999. Det kan finnas motsägelser i denna manual jämfört med levererade modeller, på grund av specialkonstruktioner, uppgraderingar och liknande.
Manualens uppbyggnad:
Manualen är uppbyggd enligt samma princip som Atlets reservdelskataloger, dvs ett system bestående av 12 flikar, där flik 4 – 12 innehåller information begränsade till ett visst område i trucken. T ex Mast (avsnitt 6) och Hydraulsystem (avsnitt 8). Flik 1 – 3 i denna manual innehåller övergripande information angående tekniska data, serviceinstruktioner samt verktyg.
Vid specifika problem och information om tillvägagångsätt, sök i innehållsförteckningen efter rätt avsnitt.
TABLE OF CONTENTS:
Atlet Truck UNS UNN UHS UFS URF USS AC Power Plus Service Manual – PDF DOWNLOAD
01............................................................................................................... 1
1 Allmän information och tekniska data....................................................................... 1
1.1 Inledning............................................................................................ 3
1.1.1 Servicemanualen................................................................................ 3
1.1.2 Truckarna...................................................................................... 3
1.2 Manualens uppbyggnad................................................................................. 4
1.2.1 Symbolförklaring............................................................................... 4
1.2.2 Historik....................................................................................... 4
1.3 Säkerhet............................................................................................. 5
1.3.1 Lyftpunkter.................................................................................... 5
1.3.2 Säkerhetsföreskrifter.......................................................................... 5
1.3.3 Miljöfarligt avfall - Miljö.................................................................... 6
1.3.4 Handhavande.................................................................................... 6
1.3.5 Felsökning..................................................................................... 7
1.4 Beteckningar......................................................................................... 8
1.4.1 Trucktyper..................................................................................... 8
1.5 Mått................................................................................................. 14
1.5.1 Måttbeskrivning UNS, UHS....................................................................... 14
1.5.2 Måttbeskrivning UFS............................................................................ 15
1.5.3 Måttbeskrivning USS............................................................................ 16
1.5.4 Måttbeskrivning URF............................................................................ 17
1.6 Komponentspecifikation............................................................................... 18
1.6.1 Drivmotor...................................................................................... 18
1.6.2 Elektrisk broms................................................................................ 18
1.6.3 Växellåda...................................................................................... 18
1.6.4 Hydraulenhet................................................................................... 19
1.6.5 Reglersystem för motor......................................................................... 19
1.6.6 Batteri........................................................................................ 20
1.6.7 Servomotor..................................................................................... 20
1.6.8 Styrservoenhet “fly by wire”................................................................... 20
1.6.9 Styrservoenhet EPS 2001........................................................................ 20
1.7 Åtdragningsmoment.................................................................................... 21
1.7.1 Omräkningstabell kraftmoment................................................................... 21
1.7.2 Skruvtyper och hållfasthetsklasser............................................................. 22
1.8 Smörjning............................................................................................ 24
1.8.1 Smörjschema UNS, UNN, UHS, USS, UFS............................................................ 24
1.8.2 Smörjschema URF................................................................................ 25
1.8.3 Symbolförklaring smörjschema................................................................... 26
1.9 Rekommenderade olje- och fettyper.................................................................... 27
1.9.1 Rekommenderade byten........................................................................... 27
1.10 Kodförklaringar..................................................................................... 28
1.10.1 Maskinfärg enligt NCS......................................................................... 28
1.10.2 Färgkoder för Atlets elscheman................................................................ 28
1.10.3 Beteckningar för elektriska komponenter....................................................... 29
1.10.4 Enheter....................................................................................... 30
02............................................................................................................... 31
2 Specialverktyg............................................................................................. 31
2.1 Verktygsförteckning.................................................................................. 33
03............................................................................................................... 35
3 Service.................................................................................................... 35
3.1 Inledning............................................................................................ 37
3.1.1 Serviceintervall............................................................................... 37
3.2 Serviceinspektion.................................................................................... 38
3.2.1 Allmänt........................................................................................ 38
3.2.2 Checklista..................................................................................... 39
3.3 Kodförklaring........................................................................................ 44
04............................................................................................................... 49
4 Chassi..................................................................................................... 49
4.1 Inledning............................................................................................ 51
4.2 Chassi, plåtar....................................................................................... 52
4.2.1 Demontering, montering av förarskyddstak....................................................... 52
4.2.2 Demontering, montering av förarskyddstolpe..................................................... 52
4.3 Chassi, maskinhusdetaljer............................................................................ 54
4.3.1 Demontering, montering av lasthjul............................................................. 54
4.3.2 Justering av dörr.............................................................................. 55
4.3.3 Batterilåsning, batterityp R................................................................... 56
4.4 Paneler.............................................................................................. 57
4.4.1 Demontering, montering av paneler.............................................................. 57
4.5 Ställbart armstöd U*S................................................................................ 58
4.5.1 Isärtagning, ihopsättning av armstöd........................................................... 58
4.6 Förarstol U*S........................................................................................ 59
4.6.1 Justering...................................................................................... 59
05............................................................................................................... 61
5 Drivenhet.................................................................................................. 61
5.1 Inledning............................................................................................ 63
5.2 Demontering, montering av åkverk..................................................................... 64
5.3 Drivmotor, allmänna anvisningar...................................................................... 65
5.3.1 Lagring av maskiner och motorer................................................................ 65
5.3.2 Första servicebesöket.......................................................................... 65
5.3.3 Förebyggande underhåll......................................................................... 65
5.3.4 Demontering, montering av motor................................................................ 66
5.3.5 Byte av Motorlager............................................................................. 67
5.3.6 Byte av lagerhus............................................................................... 68
5.4 Renovering av motor.................................................................................. 69
5.4.1 Byte av Motorlager............................................................................. 69
5.4.2 Åtdragning av mutter till drev på motoraxel.................................................... 69
5.4.3 Statorhus...................................................................................... 69
5.4.4 Montering...................................................................................... 69
5.5 Växellåda............................................................................................ 70
5.5.1 Första servicebesöket.......................................................................... 70
5.5.2 Förebyggande underhåll......................................................................... 70
5.5.3 Byte av växellåda.............................................................................. 70
5.6 Drivaxel och hjul.................................................................................... 72
5.6.1 Byte av drivaxelns packbox..................................................................... 72
5.6.2 Byte av drivhjul............................................................................... 73
5.6.3 Felsökningsschema.............................................................................. 74
06............................................................................................................... 77
6 Mast....................................................................................................... 77
6.1 Mast................................................................................................. 79
6.1.1 Demontering av mast 141, 200................................................................... 79
6.1.2 Demontering av mast 140, 160, 161.............................................................. 80
6.1.3 Justering av mässingklackar 141, 200........................................................... 82
6.1.4 Justering av mast, topp 141, 200............................................................... 82
6.1.5 Justering av mast 140, 160, 161................................................................ 83
6.1.6 Mastdämpare, nytt utförande (2003w03=>)........................................................ 87
Byte till ny mastdämpare......................................................................... 87
6.2 Släde................................................................................................ 89
6.2.7 Demontering av släde 141, 200.................................................................. 89
6.2.8 Demontering av släde 140, 160, 161............................................................. 89
6.2.9 Justering av släde 141, 200.................................................................... 89
6.2.10 Justering av släde 140, 160, 161.............................................................. 90
6.3 Gaffelvagn........................................................................................... 92
6.3.1 Justering gaffelvagn, 141, 200................................................................. 92
6.3.2 Justering gaffelvagn, 140, 160, 161............................................................ 93
6.3.3 Demontering, montering gaffelvagn.............................................................. 93
6.3.4 Gaffeltest..................................................................................... 93
6.4 Gaffelsideshiftaggregat.............................................................................. 96
6.4.1 Felsökning..................................................................................... 98
6.5 Lyftcylindrar........................................................................................ 99
6.5.1 Justering, cylinderinfästning i mast........................................................... 99
6.6 Lyftkedjor...........................................................................................100
6.6.1 Justering lyftkedjor...........................................................................100
6.6.2 Kontroll av lyftkedjor.........................................................................100
6.6.3 Regelbundet underhåll..........................................................................101
6.6.4 Återmontering av kedjor........................................................................102
6.7 Felsökning...........................................................................................103
6.7.1 Felsökningsschema 141, 200.....................................................................103
6.7.2 Felsökningsschema 140, 160, 161................................................................103
6.8 Vridgaffelaggregat typ 134 URF.......................................................................104
6.8.1 Säkerhetsföreskrifter..........................................................................104
6.8.2 Allmän beskrivning.............................................................................105
6.8.3 Monteringsinstruktion..........................................................................106
6.8.4 Åtdragningsmoment [Nm].........................................................................108
6.8.5 Gänganslutning.................................................................................108
6.8.6 Funktionstest..................................................................................109
6.8.7 Hydrauliska ledningar och anslutningar.........................................................109
6.8.8 Justering......................................................................................112
6.8.9 Gaffelhållare..................................................................................112
6.8.10 Rotationscylindrar............................................................................113
6.8.11 Bom...........................................................................................113
6.8.12 Excenterjustering.............................................................................113
6.8.13 Pinjongdrivaxel...............................................................................115
6.8.14 Stödrullar....................................................................................115
6.8.15 Hydraulisk motor..............................................................................116
6.8.16 Arbetsförhållanden och isärtagning av motorer.................................................117
6.8.17 Inspektionlista...............................................................................118
07...............................................................................................................121
7 Styrning...................................................................................................121
7.1 Inledning............................................................................................121
7.1.1 Kapitelstruktur................................................................................123
7.1.2 Övergripande beskrivning - fly by wire-styrning................................................123
7.1.3 Övergripande beskrivning - EPS 2001-styrning...................................................124
7.2 Styrservomotor.......................................................................................126
7.2.1 Justering av styrservosystem - fly by wire.....................................................126
7.2.2 Demontering av styrservomotor..................................................................126
7.3 Inställningar, justeringar och test..................................................................127
7.3.1 Regulator, funktioner - fly by wire............................................................127
7.3.2 Inställningar av regulator - fly by wire.......................................................127
7.3.3 Regulatorns fabriksinställningar - fly by wire.................................................128
7.3.4 Funktionskontroll av styrservosystem - fly by wire.............................................129
7.3.5 Mekanisk justering av styrningsgivare - EPS 2001...............................................129
7.3.6 Funktionstest av styrningsgivare - EPS 2001....................................................130
7.3.7 Kalibrering av givarsystem - EPS 2001..........................................................130
7.3.8 Inställning av styrhjulsindikator - EPS 2001...................................................130
7.3.9 Kalibrering av rakstyrning - URF EPS 2001......................................................131
7.3.10 Förarinställning av styrkänslighet - EPS 2001.................................................131
7.4 Optioner.............................................................................................132
7.4.1 Begränsad eller ändlös styrning - EPS 2001.....................................................132
7.4.2 Mini- eller midiratt - EPS 2001................................................................132
7.5 Diagnostik och felsökning............................................................................133
7.5.1 Fly by wire....................................................................................133
7.5.2 EPS 2001.......................................................................................134
08...............................................................................................................135
8 Hydraulsystem..............................................................................................135
8.1 Inledning............................................................................................137
8.1.1 Beskrivning....................................................................................137
8.2 Hydraulsystem - generella regler.....................................................................139
8.2.1 Installation...................................................................................139
8.2.2 Anslutningar...................................................................................139
8.2.3 Uppstart.......................................................................................139
8.2.4 Monteringsinstruktion för rörkopplingar........................................................140
8.3 Hydraulfilter........................................................................................144
8.3.1 Byte...........................................................................................144
8.4 Pumpmotor............................................................................................145
8.4.1 Demontering....................................................................................145
8.4.2 Byte av Motorlager.............................................................................146
Demontering......................................................................................146
Montering........................................................................................147
8.4.3 Byte av lagerhus...............................................................................147
Montering........................................................................................147
8.4.4 Montering......................................................................................147
8.5 Sugslang.............................................................................................148
8.5.1 Byte...........................................................................................148
8.6 Tank.................................................................................................149
8.6.1 Tömning........................................................................................149
8.7 Cylindrar............................................................................................150
8.7.1 Demontering av mastförskjutningscylinder.......................................................150
8.7.2 Isärtagning, ihopsättning av mastförskjutningscylinder.........................................150
8.7.3 Luftning av mastförskjutningscylinder..........................................................151
8.7.4 Luftning av mastförskjutningscylinder..........................................................152
8.8 Ventiler.............................................................................................154
8.8.1 Handhavande av manöverventil...................................................................154
8.8.2 Justering av arbetstryck.......................................................................155
8.8.3 Nödsänkventil..................................................................................155
8.8.4 Felsökning manöverventil.......................................................................156
8.8.5 Inställning av slangbrottsventil...............................................................157
8.9 Hydraulreglage.......................................................................................158
8.9.1 Kalibrering....................................................................................158
8.10 Hydraulschema.......................................................................................159
8.10.1 Revisionslista................................................................................159
09...............................................................................................................167
9 Lyftcylindrar..............................................................................................167
9.1 Frilyftcylinder......................................................................................169
9.1.1 Demontering....................................................................................169
9.1.2 Isärtagning....................................................................................169
9.1.3 Avtappning, luftning...........................................................................170
9.2 Slutslagcylinder.....................................................................................172
9.2.1 Demontering....................................................................................172
9.2.2 Isärtagning....................................................................................172
9.3 Frilyftcylinder URF..................................................................................174
9.3.1 Demontering....................................................................................174
9.3.2 Luftning.......................................................................................180
9.4 Frilyftcylinder URF, äldre design....................................................................181
9.4.1 Isärtagning....................................................................................181
9.5 Frilyftcylinder URF, nyare design....................................................................185
9.5.1 Isärtagning....................................................................................185
10...............................................................................................................189
10 Elsystem.................................................................................................. 0
10.1 Inledning...........................................................................................193
10.1.1 Komponentbeskrivning..........................................................................193
10.1.2 Säkerhet......................................................................................193
10.2 Batteri.............................................................................................195
10.2.1 Byte..........................................................................................195
10.2.2 Kapacitetsmätning.............................................................................195
10.2.3 Batteriparametrar fr o m version 3.00.........................................................198
10.3 Chassi..............................................................................................199
10.3.1 Kontroll av anslutning mellan ATC - chassi....................................................199
10.3.2 Potentialmätning..............................................................................199
10.3.3 Optisk sensor, skenstyrning...................................................................199
10.3.4 Länkhjulslåsning, UFS.........................................................................201
Nytt utförande av länkhjul.......................................................................201
Funktionsbeskrivning.............................................................................201
Service och felsökning...........................................................................201
Ny felkod........................................................................................202
10.4 Kontakter i frysrum.................................................................................203
10.4.1 Infettning....................................................................................203
10.5 Driv- och pumpregulator (2005w04-)..................................................................204
10.5.1 Demontering, montering........................................................................204
10.5.2 Benämning.....................................................................................204
10.5.3 Allmänt om reglering av AC-motorer............................................................204
10.5.4 Anslutningar..................................................................................204
10.5.5 Kablageanslutningar...........................................................................204
10.5.6 Effektkablage.................................................................................205
10.6 Isolationsmotstånd..................................................................................206
10.6.1 Rutintest.....................................................................................206
10.7 Temperaturmätning...................................................................................207
10.7.1 Felsökning - hydraulfunktionerna kanal 3, 4 och 5.............................................208
10.8 Magnetbrytaren till mastförskjutningsstoppet........................................................209
10.8.1 Mastförskjutningsstopp........................................................................209
10.8.2 Mastförskjutningsdämpning (2005w04-) (truckar med S3).........................................210
Dämpning av reach-in rörelsen....................................................................210
Dämpning av reach-ut rörelsen....................................................................211
10.9 Säkringar...........................................................................................212
10.9.1 Standard......................................................................................212
10.9.2 Extra tillbehör...............................................................................212
10.10 Signalhorn.........................................................................................213
10.10.1 Inkoppling...................................................................................213
10.11 Atlets truckdator ATC..............................................................................214
10.11.1 Komponent- och gränssnittsbeskrivning........................................................214
Display:.........................................................................................214
10.11.2 Handhavande..................................................................................215
10.11.3 Servicefunktioner............................................................................216
10.11.4 Ändring av lösenord..........................................................................216
10.11.5 Kalibrering och kontroll av hydraulspakarna..................................................216
10.11.6 Drifttidsfunktioner..........................................................................216
10.11.7 Utskrifter av statistik......................................................................217
10.11.8 Krocksensor..................................................................................217
10.11.9 Kontakter ATC................................................................................217
10.11.10 Kontroll av ingångar och utgångar...........................................................217
10.11.11 Digitala ingångar...........................................................................218
10.11.12 Digitala utgångar “XC1-XC11”................................................................219
10.11.13 Digitala utgångar, B+ matade................................................................221
10.11.14 Digitala utgångar 12 V-matade...............................................................221
10.11.15 Digitala utgångar B+ matningar..............................................................222
10.11.16 Ventilparametrar............................................................................222
Parameterbeskrivning.............................................................................222
Kontroll och justering av värden.................................................................223
10.11.17 Prestandaparametrar.........................................................................223
Inställning av maskinparametrar..................................................................223
Inställning av förarkategorier...................................................................223
Fabriksinställda värden..........................................................................225
Individuella förarinställningar..................................................................225
10.12 Felkoder...........................................................................................227
10.12.1 Allmänt......................................................................................227
10.12.2 Felkodsbeskrivning...........................................................................228
10.13 Varningar..........................................................................................245
10.13.1 Beskrivning..................................................................................245
10.14 Menyträd ATC.......................................................................................246
10.14.1 Loggbok över fel.............................................................................246
10.14.2 Subinfo......................................................................................246
10.14.3 Generella anvisningar vid alla typer av fel i truckar i kombination med spänningsbortfall....246
ATC fungerar inte normalt........................................................................246
B+ eller B- avviker..............................................................................246
B+2 avviker......................................................................................246
B+3 avviker......................................................................................247
B+4 avviker......................................................................................247
B+5 avviker......................................................................................247
AGND avviker.....................................................................................247
B5V avviker......................................................................................247
B12V avviker.....................................................................................247
10.15 Felsökning - driftsstörning........................................................................248
10.15.1 Truck och ATC................................................................................248
10.15.2 Batteri......................................................................................249
10.15.3 Huvudkontaktor...............................................................................249
10.15.4 Säkring......................................................................................250
10.15.5 Drivregulatorns statusindikator..............................................................251
10.15.6 Drivmotor....................................................................................252
10.15.7 Pumpmotor....................................................................................256
10.15.8 Pumpregulatorns statusindikator..............................................................259
10.15.9 Styrsystem - EPS 2001........................................................................260
10.15.10 Drivfunktionen..............................................................................261
10.15.11 Gafflar.....................................................................................263
10.15.12 Automatisk vridning av drivenhet - UFS......................................................268
10.15.13 Vridhjulsindikering - UFS...................................................................269
10.15.14 Låg temp drive/Låg temp hydraul.............................................................269
10.15.15 High/Low voltage - EPS 2001.................................................................269
10.15.16 High temp Steering/Overheated steer - EPS 2001..............................................270
10.16 Felsökning - felmeddelande.........................................................................271
10.16.1 E05, E06, E07, Elservo - fly by wire.........................................................271
10.16.2 CAN..........................................................................................272
10.16.3 E97, E98, Drivsys stoppat/Hydraul stoppad....................................................273
10.16.4 E100, E101, Drivsys onormalt/Hydraul onormal.................................................277
10.16.5 E102, E103, E107 Servo stoppat/Servo onormalt - EPS 2001.....................................279
10.16.6 E105, Drivsystem.............................................................................283
10.16.7 E106, Pumpsystem.............................................................................285
10.17 Felsökningstabell - batteri........................................................................288
10.17.1 Batteristopp.................................................................................288
10.18 Elscheman..........................................................................................289
10.19 Bilaga 1 Menyträd..................................................................................290
Service meny.........................................................................................290
Språkval.............................................................................................290
Lokal service........................................................................................290
ATLET service........................................................................................290
Kundservice..........................................................................................290
Uppstart.............................................................................................290
Fjärrservice.........................................................................................290
Logged on service....................................................................................290
11...............................................................................................................332
11 Fart- och bromssystem.....................................................................................332
11.1 Fartreglage.........................................................................................334
11.1.1 Demontering av fart och bromsreglage..........................................................334
11.1.2 Kontroll och justering av fartreglage.........................................................334
11.1.3 Gillgivare....................................................................................335
In- och utgångar.................................................................................335
11.1.4 Kalibrering av fartreglage (Gillgivare).......................................................335
11.1.5 Kalibrering av fartreglage (SLOAN)............................................................337
11.2 Bromspedal..........................................................................................339
11.2.1 Justering och kontroll av bromsreglage........................................................340
11.2.2 Kalibrering av UFS bromspedal.................................................................342
11.3 Vänsterfotsbrytare..................................................................................343
11.3.1 Demontering, montering av vänsterfotsbrytare..................................................343
11.3.2 Justering av vänsterfotsbrytare...............................................................344
11.3.3 Förebyggande underhåll........................................................................344
11.4 Elbroms.............................................................................................345
11.4.1 Elbroms, 1-skivig (-2003w01)..................................................................345
Justering........................................................................................345
11.4.2 Elbroms (2003w02-)............................................................................346
Nödfrikoppling...................................................................................346
Service..........................................................................................347
11.5 Felsökning..........................................................................................348
11.5.1 Bromsen släpper inte..........................................................................348
12...............................................................................................................350
12 Extra tillbehör........................................................................................... 0
12.1 Nivåväljare.........................................................................................352
12.1.1 Inställning av brytarhöjdförval...............................................................353
12.1.2 Höjdförval....................................................................................353
12.1.3 Handhavande höjdförval........................................................................353
12.1.4 Pulshöjdförval................................................................................354
12.1.5 Handhavande...................................................................................354
12.1.6 Kontroll av inställning.......................................................................355
12.1.7 Exempel på användning.........................................................................355
12.2 Höjdmätarinstrument.................................................................................357
12.2.1 Allmänt.......................................................................................357
12.2.2 Teknik........................................................................................357
12.2.3 Inställningar.................................................................................357
12.2.4 Programmering.................................................................................357
12.2.5 Inställning av offsetvärde....................................................................357
12.2.6 Skydda förinställda värden....................................................................358
12.2.7 Inställning av COEFF..........................................................................358
12.2.8 Inställning av dECPt..........................................................................358
12.2.9 Sluttest......................................................................................358
12.2.10 Givare.......................................................................................358
12.2.11 Justering av givare..........................................................................358
12.2.12 Höjdvisning i display........................................................................358
12.3 Hytt................................................................................................359
12.3.1 Värme och ventilation.........................................................................359
Funktion hyttvärmare (2004w50-)..................................................................359
Underhåll........................................................................................360
Konfiguration och programversion.................................................................361
Överhettningsskydd...............................................................................361
12.4 Ergologic...........................................................................................362
12.4.1 Elektrisk kalibrering.........................................................................362
12.4.2 Mekanisk justering av lyft/sänkpotentiometer..................................................363
12.5 Semiautomatisk tiltcentrering.......................................................................364
12.6 Semiautomatisk sideshiftcentrering..................................................................365
12.7 Stability Support System, S3........................................................................366
12.7.1 Identifiering.................................................................................366
12.7.2 Funktionsbeskrivning..........................................................................366
12.7.3 Åkhastighet...................................................................................367
12.7.4 Hydraulfunktioner.............................................................................368
12.7.5 Teknisk beskrivning...........................................................................369
12.8 S3 alternativ 2 (S3-2), viktindikering..............................................................370
12.8.1 Funktion......................................................................................370
12.8.2 Teknisk beskrivning...........................................................................370
12.8.3 Kalibrering...................................................................................370
12.9 Truck Remote ACcess, TRAC...........................................................................373
Förutsättningar......................................................................................373
Att använda..........................................................................................373
Anslutningsprocedur..................................................................................373
