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ATLET Truck X-Ergo XTF-Ergo XLL-Ergo XML-Ergo Service Manual – PDF DOWNLOAD
Original price was: $65.95.$29.95Current price is: $29.95.
ATLET Truck X-Ergo XTF-Ergo XLL-Ergo XML-Ergo Service Manual – PDF DOWNLOAD
Machine: X-Ergo
Manual No: 005997
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Description
ATLET Truck X-Ergo XTF-Ergo XLL-Ergo XML-Ergo Service Manual – PDF DOWNLOAD
DESCRIPTION:
ATLET Truck X-Ergo XTF-Ergo XLL-Ergo XML-Ergo Service Manual – PDF DOWNLOAD
Machine: X-Ergo
Manual No: 005997
Introduction
Service manual :
Service manual :
The manual describes the service procedures on ATLET reach trucks in the U** AC Power Plus range. Use the manual for quick and correct service of respective truck models. The manual describes models manufactured from the introduction of Mark 2 at the end of 1999. You may find contradictions in the manual compared to the models supplied due to optional designs and the like.
Scope of X-Ergo :
The Sit-on stacker trucks in the X-Ergo series are available in a number of different variants with mast system, adjustable straddle lift, extendable stabilisers and telescopic forks.
How to use the manual
Structure
Structure
- The manual is built up according to the same principles as ATLET spare parts catalogues, with the truck divided into one subsystem per section.
- Sections 1 – 3 in this manual contain more comprehensive information regarding technical data, general service instructions and tools.
- Sections 4-12 in this manual contain information limited to a specific area in the truck concerning the description of the mechanical handling of different components, e.g. Masts (section 6) and Hydraulic System (section 8).
- The software is described in section 10.
- The main principle for extra accessories is to place them under the respective sections. Otherwise they are placed under section 12 “Miscellaneous”. For this reason section 12 is not always included in the Service Manual.
- For specific problems or information about procedures, look in the main index for the correct section in the manual.
TABLE OF CONTENTS:
ATLET Truck X-Ergo XTF-Ergo XLL-Ergo XML-Ergo Service Manual – PDF DOWNLOAD
01.................................................................................... 1 1 General information and technical data.......................................... 1 Scope of Service Manual....................................................... 3 General................................................................... 3 Scope of X-Ergo........................................................... 4 How to use the manual......................................................... 5 Structure................................................................. 5 Symbol key................................................................ 5 Safety instructions........................................................... 6 General................................................................... 6 Lifting the truck......................................................... 7 Welding on the truck...................................................... 8 Atlet AB takes care of the environment.................................... 8 Environmental impact...................................................... 8 Waste..................................................................... 8 Preparations.................................................................. 9 Service................................................................... 9 Trouble shooting.......................................................... 9 Data X-Ergo................................................................... 10 Designations.............................................................. 10 Dimensions and weights.................................................... 15 Component specification................................................... 22 Recommended consumable materials.............................................. 23 Oil and grease............................................................ 23 Standards and abbreviations................................................... 24 Tightening torque, screws and nuts........................................ 24 Tightening torque, hydraulic couplings.................................... 24 Conversion tables......................................................... 25 Standard abbreviations.................................................... 26 Screw types and tensile grades............................................ 26 Colour of the truck....................................................... 27 Colour codes, cabling..................................................... 28 Designations for electrical components.................................... 29 02.................................................................................... 31 2 Special tools................................................................... 31 Special tools X-Ergo.......................................................... 33 Introduction.............................................................. 33 List of tools............................................................. 33 Dismantling tool, buttons and lamps................................... 33 Other tools........................................................... 34 03.................................................................................... 35 3 Service......................................................................... 35 Regular maintenance 3......................................................... 37 Introduction.............................................................. 37 Safety.................................................................... 37 Recommendations........................................................... 37 Daily inspection.......................................................... 38 Weekly inspection (30 hours of operation)................................. 39 First service............................................................. 39 Main service.............................................................. 39 Extra service inspections................................................. 40 Check list, service inspection............................................ 41 Code explanation.......................................................... 46 Lubrication chart......................................................... 50 Specific instructions......................................................... 54 Drive motor............................................................... 54 Gearbox................................................................... 54 Drive unit................................................................ 55 Lift chains and forks..................................................... 55 Overhead guard............................................................ 55 Mast...................................................................... 56 Hydraulic oil............................................................. 57 Recommended replacement................................................... 57 Storage of machines and motors............................................ 57 04.................................................................................... 59 4 Chassis......................................................................... 59 Design and function........................................................... 61 Scope..................................................................... 61 Machine housing........................................................... 61 Overhead guard............................................................ 61 Elbow rest, driver seat and foot plate.................................... 62 Panels.................................................................... 62 Castor wheel.............................................................. 62 Repair instructions........................................................... 63 Overhead guard............................................................ 63 Elbow rest................................................................ 64 Panels.................................................................... 66 Driver seat............................................................... 67 Floor plate............................................................... 68 Castor wheel.............................................................. 70 Adjusting the angle of the truck.......................................... 71 Replacing the drive wheel................................................. 71 Battery................................................................... 72 05.................................................................................... 73 5 Drive unit...................................................................... 73 Design and function........................................................... 75 Introduction.............................................................. 75 Traction motor............................................................ 75 Gearbox................................................................... 75 Repair instructions........................................................... 76 Preparations.............................................................. 76 Replacing the drive unit.................................................. 76 Traction motor............................................................ 77 Gearbox................................................................... 79 Reconditioning the gearbox................................................ 81 Drive wheel, replacement.................................................. 86 Diagnostics and trouble shooting.............................................. 87 Trouble shooting chart.................................................... 87 06.................................................................................... 89 6 Mast system..................................................................... 89 Design and function........................................................... 91 Mast system............................................................... 91 Fork carriage............................................................. 92 Straddle lift............................................................. 94 Side stabilisers.......................................................... 95 Repair instructions........................................................... 96 Replacing the mast/straddle lift.......................................... 96 Dismantling the mast......................................................101 Lift chains...............................................................108 Forks.....................................................................110 Fork carriage, general....................................................113 Fork carriage, telescopic forks, TF.......................................114 Adjustable straddle lift..................................................122 Side stabilisers..........................................................124 Push rods XLL.............................................................125 Diagnostics and trouble shooting..............................................126 Trouble shooting chart....................................................126 07....................................................................................127 7 Steering........................................................................127 Design and function...........................................................129 General...................................................................129 Steering..................................................................129 Controller steering motor.................................................129 Repair instructions...........................................................130 Steering wheel, stepper motor sensor......................................130 Steering motor with gearbox...............................................130 Replacing the steering controller sensor..................................131 Diagnostics and trouble shooting..............................................132 08....................................................................................133 8 Hydraulic system................................................................133 Hydraulic diagram, Electric proportional valve (-2008w45).....................138 Hydraulic diagram XLL.........................................................142 Hydraulic diagram, Electric proportional valve (2008w46-).....................140 Design and function...........................................................135 General...................................................................135 Lifting...............................................................135 Lowering..............................................................135 Hose-break valve..........................................................135 Electric control valve....................................................136 General...............................................................136 Lifting function......................................................136 Lowering function.....................................................136 Lowering speed regulator function.....................................136 Hydraulic diagram.........................................................136 Repair instructions...........................................................144 Hydraulic system..........................................................144 General rules.........................................................144 Installation..........................................................144 Connections...........................................................145 Start up..............................................................145 Hydraulic oil, changing/draining..........................................146 Properties of the hydraulic oil.......................................146 Requisite equipment...................................................146 Procedure.............................................................146 Air filter, replacing.....................................................148 Oil filter insert, replacing..............................................149 Checking the hydraulic oil level..........................................149 Hose-break valve..........................................................150 Dismantling and assembling............................................150 Control valve.............................................................152 General instructions when working with control valve..................152 Electrically operated control valve, dismantling and assembling.......153 Checking the lowering speed...........................................154 Adjusting the regulator, electric valve...............................154 Adjusting the lowering speed valve in the electric hydraulic valve....154 Adjusting the working pressure........................................155 Emergency lowering valve..............................................155 Hydraulic pump motor......................................................156 Dismantling the hydraulic pump motor..................................156 Inspection of pump motor X-Ergo.......................................157 Hydraulic pump motor XLL..................................................158 When should the brushes be replaced?..................................158 Replacing the brushes.................................................158 Tips to prolong the service-life of the motor.........................160 Stabiliser cylinders......................................................161 Dismantling and assembling the stabiliser cylinders...................161 Dismantling and assembling, gaskets...................................161 Installation instructions for pipe couplings..............................162 Diagnostics and trouble shooting..............................................165 Symptom and Action........................................................165 09....................................................................................167 9 Lift cylinders..................................................................167 Design and function...........................................................169 Introduction..............................................................169 Repair instructions...........................................................170 General...................................................................170 Free-lift cylinder TFV/DTFV...............................................171 Lift cylinder TV/TFV/DTFV.................................................173 Lift cylinder T...........................................................176 10....................................................................................179 10 Electrical system..............................................................179 Design and function...........................................................183 General...................................................................183 Description of components.............................................183 Description of components and interface...............................184 Power steering controller, EPS-AC.........................................185 Function, power steering controller EPS-AC............................186 Connector, specification, power steering controller EPS-AC............188 S3 - Stability Support System.............................................190 Repair instructions...........................................................192 General...................................................................192 Safety procedures.....................................................192 Abbreviations.........................................................193 Battery...................................................................193 Battery capacity......................................................193 General handling..........................................................195 Function keyboard.....................................................195 Menu tree - start-up and top level....................................196 Contactors in cold storage rooms..........................................197 Greasing..............................................................197 Drive and valve controller................................................198 Connector traction motor controller, specification....................198 Wiring diagram............................................................199 Insulation resistance.....................................................200 Routine test..........................................................200 Main controller unit ATC, Handling........................................200 Settings..............................................................202 Total Reset...........................................................202 Set Truck Type........................................................202 Monitor menu..........................................................203 Set options...........................................................204 Calibrate accelerator.................................................204 Calibrate brake.......................................................205 Calibrate lift/lower..................................................205 Add new driver........................................................206 Change format of driver ID and access code............................206 Change access code for Local or Atlet service menu....................207 Log functions and hour counter........................................207 Read hour counter.....................................................208 Temperature log.......................................................208 Error log.............................................................209 Read error log........................................................210 Clear error log.......................................................210 Performance parameters................................................211 Driver categories.....................................................212 Set driver parameters.................................................212 PIN code..............................................................212 Safety checks.........................................................213 Speed limits..........................................................213 General functional description........................................214 Truck mode............................................................214 Temperatures..........................................................215 Options...............................................................216 Download of service data and logs to a PC.............................217 Download of "Truck Manager" statistical logs to a PC..................218 ATC connector.........................................................219 Digital I/Os..........................................................219 ATC Logic, general........................................................221 Lift system...............................................................223 Lift system, general..................................................223 Adjustable straddle legs..............................................224 Stabilizors...........................................................225 Brake system..............................................................226 Drive system..............................................................227 Cold resistance values X-ergo.............................................228 Fuses.....................................................................228 Overview of menu tree.....................................................229 Menu tree Local menu..................................................229 Menu tree Atlet menu..................................................230 Menu tree Monitor menu................................................240 Menu tree Reset menu..................................................240 Menu tree Language....................................................241 Menu tree TRAC........................................................241 Diagnostics and trouble shooting..............................................242 Truck Remote ACcess, TRAC.................................................242 Prerequisites.........................................................242 Utilization...........................................................242 Connecting procedure..................................................242 Error Codes...............................................................243 Error code indicating ATC:............................................243 Error code indicating EPS:............................................246 Error code indicating TMC:............................................249 Error code indicating HVC:............................................253 Error code indicating HVC2:...........................................256 11....................................................................................259 11 Brake and traction system......................................................259 Design and function...........................................................261 Electric brake............................................................261 Accelerator and brake sensor (Gill sensor)................................261 Repair instructions...........................................................263 Electric brake............................................................263
ATLET TRUCK X-ERGO XTF-ERGO XLL-ERGO XML-ERGO SERVICE MANUAL – PDF DOWNLOAD:
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