STILL STED Forklift FM-4W 25 (ATLET UFS) Reach mast stacker workshop Manual – PDF DOWNLOAD

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STILL STED Forklift FM-4W 25 (ATLET UFS) Reach mast stacker workshop Manual – PDF DOWNLOAD

FILE DETAILS:

STILL STED Forklift FM-4W 25 (ATLET UFS) Reach mast stacker workshop Manual – PDF DOWNLOAD

Language : English
Pages : 440
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

STILL STED Forklift FM-4W 25 (ATLET UFS) Reach mast stacker workshop Manual – PDF DOWNLOAD

General information and technical data
1.1 Introduction
1.1.1 Service Manual

• The manual describes the servicing procedures for 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 and including the introduction of the Mark 2 at the end of 1999.
• You may find contradictions in this Manual compared to the models supplied due to special design features, upgrades, and other detail differences. The content of this manual is protected by copyright law and may not be copied, fully or in part, without written permission.
• The material has undergone careful examination with regard to correctness. We reserve the right to make changes. In the event of inconsistent information in the Swedish and translated editions, it is the Swedish edition that applies. Modifications and updates will be distributed via ATLET AB Service Manual Change.

TABLE OF CONTENTS:

STILL STED Forklift FM-4W 25 (ATLET UFS) Reach mast stacker workshop Manual – PDF DOWNLOAD

Introduction 1 3
Service Manual 1 3
The trucks 1 3
Structure of the Manual 1 4
Symbol key 1 4
History 1 4
Safety 1 6
Lifting points 1 6
Safety instructions 1 7
Truck modification 1 7
Environmentally hazardous waste – Environment 1 8
Operation 1 8
Trouble shooting 1 9
Designations 1 10
Truck types 1 10
Measurements 1 15
Dimensional descriptions UNS, UHS 1 15
Dimensional descriptions UFS 1 16
Dimensional descriptions USS 1 17
Dimensional descriptions URF 1 18
Component specification 1 19
Traction motor 1 19
Electric brake 1 19
Gearbox 1 19
Hydraulic unit 1 20
Control system for motor 1 20
Battery 1 21
Servo motor 1 21
“Fly By Wire” servo control unit 1 21
Steering servo unit EPS 2001 1 21
Tightening torque 1 22
Conversion table torque 1 22
Screw types and tensile grades 1 23
Recommended oil and grease types 1 25
Code explanations 1 28
List of contents
SERVICE MANUAL U AC POWER PLUS
Machine colours according to NCS 1 28
Colour codes for Atlet’s wiring diagrams 1 28
Designations for electrical components 1 29
Units 1 30
Edition 2005C
2 Special tools
List of tools 2 3
Edition 2011A
3 Service
Introduction 3 3
Service intervals 3 3
Service inspection 3 4
General 3 4
Check list 3 5
Code explanation 3 12
Lubrication 3 16
Recommended replacements 3 16
Lubrication chart for UNS, UNN, UHS, USS, UFS 3 17
Lubrication chart URF 3 18
Symbol key lubrication chart 3 19
Edition 2009B
4 Chassis
Introduction 4 3
Chassis, plates 4 4
Dismantling, assembling the overhead guard 4 4
Dismantling, assembling the overhead guard stanchion 4 4
Chassis, machine housing components 4 6
Dismantling, assembling the rail wheel 4 6
Adjusting stabilizing lugs (UHH) 4 7
Adjusting the door 4 8
List of contents
SERVICE MANUAL U AC POWER PLUS
Battery lock, battery type R 4 9
Panels 4 10
Dismantling, assembling the panels 4 10
Adjustable arm rest U*S 4 11
Dismantling, assembling the arm rest 4 11
Driver seat U*S 4 12
Adjustments 4 12
Edition 2013B
Drive unit
Introduction 5 3
Dismantling, assembling the dive unit 5 4
Drive motor, general instructions 5 5
Storage of machines and motors 5 5
First service 5 5
Preventive maintenance 5 5
Dismantling, assembling the motor 5 6
Changing the motor bearings 5 7
Replacing the bearing housing 5 8
Reconditioning the motor 5 9
Changing the motor bearings 5 9
Pinion nut tightening torque 5 9
Stator housing 5 9
Installation 5 9
Gearbox 5 10
First service 5 10
Preventive maintenance 5 10
Replacing the gearbox 5 10
Drive shaft and wheel 5 12
Replacing the drive shaft’s stuffing box 5 12
Replacing the drive wheel 5 13
Troubleshooting chart 5 13
Mast 6 3
Dismantling the 121 or 200 masts 6 3
Dismantling the 140, 160 or 161 mast 6 5
Adjusting the brass lugs on 141 and 200 6 7
Adjusting the 141 or 200 mast top 6 7
Adjusting a 140, 160 or 161 mast 6 8
Mast damper, new design (2003w03=>) 6 12
Reach carriage 6 14
Dismantling the 141 or 200 reach carriage 6 14
Dismantling the 140, 160, or 161 reach carriage 6 14
Adjusting the 141 or 200 reach carriage 6 14
Adjusting the 140, 160 or 161 reach carriage 6 15
Fork carriage 6 17
Adjusting the 141 or 200 fork carriage 6 17
Adjusting the 140, 160 or 161 fork carriage 6 18
Dismantling, assembling the fork carriage 6 18
Fork test 6 19
Fork side shift unit 6 21
Trouble shooting 6 23
Lift cylinders 6 24
Adjusting the cylinder attachment in the mast 6 24
Lift chains 6 25
Adjusting the lift chains 6 25
Checking the lift chains 6 25
Regular maintenance 6 26
Re-fitting the chains 6 27
Inspection of forged forks 6 28
Trouble shooting 6 33
141 and 200 Troubleshooting chart 6 33
Troubleshooting chart for 140, 160 and 161 6 33
Swivel forks unit type 134 URF 6 34
Safety instructions 6 34
General description 6 35
Assembly instructions 6 36
Tightening torque [Nm] 6 38
List of contents
SERVICE MANUAL U AC POWER PLUS
Threaded connection 6 38
Function test 6 39
Hydraulic lines and connections 6 39
Adjustment 6 42
Fork holder 6 42
Rotation cylinders 6 43
Boom 6 43
Cam adjustment 6 43
Pinion drive shaft 6 45
Thrust rollers 6 45
Hydraulic motor 6 46
Working conditions and motor dismantling 6 47
Inspection list 6 48
Introduction 7 3
Section structure 7 3
General description – fly by wire control 7 3
General description – EPS 2001 control 7 4
General description – EPS AC0 control 7 5
Repair and maintenance instructions 7 7
Steering servo motor 7 7
Settings, adjustments and testing 7 9
Options 7 14
Diagnostics and troubleshooting 7 15
Fly By Wire 7 15
EPS 2001 7 16
EPS AC0 7 17
Introduction 8 3
Descriptions 8 3
Hydraulic system – general regulations 8 5
List of contents
SERVICE MANUAL U AC POWER PLUS
Installation 8 5
Connections 8 5
Start up 8 5
Installation instruction for pipe unions 8 6
Hydraulic filter 8 10
Replacement 8 10
Pump motor 8 11
Dismantling 8 11
Changing the motor bearings 8 12
Replacing the bearing housing 8 13
Installation 8 13
Suction hose 8 14
Replacement 8 14
Tank 8 15
Emptying 8 15
Cylinders 8 16
Removing the reach cylinder 8 16
Dismantling, assembling the reach cylinder 8 16
Bleeding the reach cylinder 8 17
Valves 8 19
Operation of the control valve 8 19
Adjusting the working pressure 8 20
Emergency lowering valve 8 20
Trouble shooting the control valve 8 21
Setting the hose rupture valve 8 22
Hydraulic control 8 23
Calibration 8 23
Hydraulic diagram 8 24
Revision history 8 24
Edition 2004B
9 Lift cylinders
Free lift cylinder 9 3
Dismantling 9 3
Dismantling 9 3
Draining, bleeding 9 4
Final stroke cylinder 9 6
List of contents
SERVICE MANUAL U AC POWER PLUS
Dismantling 9 6
Dismantling 9 6
Free lifting cylinder URF 9 8
Dismantling 9 8
Bleeding 9 14
Free-lift cylinder URF, older model 9 15
Dismantling 9 15
Free-lift cylinder URF, newer model 9 19
Dismantling 9 19
Edition 2013B
Electrical system
Introduction 10 5
Component descriptions 10 5
Safety 10 5
Battery 10 7
Replacement 10 7
Battery capacity measurement 10 7
Battery parameters from version 3 00 onwards 10 9
Chassis 10 10
Checking the connection between ATC and the chassis 10 10
Measuring potential 10 10
Optical sensor, rail guided steering 10 11
Caster wheel rotation lock, UFS 10 12
Connectors in cold storage rooms 10 14
Greasing 10 14
Drive and pump controllers (2005w04–) 10 15
Dismantling and assembling 10 15
Description 10 15
General information concerning AC motors 10 15
Connections 10 15
Wiring connections 10 16
Power cabling 10 16
Insulation resistance 10 17
Routine test 10 17
Temperature measurement 10 18
List of contents
SERVICE MANUAL U AC POWER PLUS
Trouble shooting of the hydraulic functions, channels 3, 4 and 5 10 19
Solenoid switch for the mast reach stop 10 20
Mast reach stop 10 20
Mast reach cylinder damping (2005w04–) (trucks with S3) 10 21
Fuses 10 23
Standard 10 23
Extra accessories 10 23
Horn 10 24
Connection 10 24
Atlet’s truck computer ATC 10 25
Description of components and interface 10 25
Operation 10 26
Service functions 10 27
Change passwords 10 27
Calibration and control of the hydraulic levers 10 27
Running time functions 10 28
Printing of statistics 10 28
Collision sensor 10 28
ATC connector 10 28
Checking the inputs and outputs 10 29
Digital inputs 10 29
Digital outputs “XC1-XC11” 10 31
Digital outputs, B+ supply 10 32
Digital outputs, 12 V supply 10 34
Digital outputs B+ supply 10 34
Valve parameters 10 34
Performance parameters 10 35
Presence control 10 41
Error codes 10 42
General 10 42
Error code descriptions 10 42
Warnings 10 58
Descriptions 10 58
Menu tree ATC 10 59
Log of faults 10 59
Subinfo 10 59
General instructions for all types of truck faults in combination with a loss of voltage
10 59
Trouble shooting – operational disturbances 10 61
List of contents
SERVICE MANUAL U AC POWER PLUS
Truck and ATC 10 61
Battery 10 62
Main contactor 10 62
Fuse 10 63
Drive controller status indicator 10 65
Traction motor 10 66
Pump motor 10 69
Pump controller status indicator 10 73
Steering system – EPS 2001 10 75
The drive function 10 76
Forks 10 78
Automatic turning of the drive wheel – UFS 10 86
Steered wheel indication – UFS 10 86
Low temperature drive or Low temperature hydraulics 10 86
High/low voltage – EPS 2001 10 87
High temp Steering/Overheated steer – EPS 2001 10 88
Trouble shooting – error messages 10 89
E05, E06, E07, Electric servo – Fly By Wire control 10 89
CAN 10 90
E97, E98, Drive system stopped/ Hydraulics stopped 10 91
E100, E101, Drive system abnormal/ Hydraulics abnormal 10 96
E102, E103, E107 Servo stopped/Servo abnormal – EPS 2001 10 99
E105, Drive system 10 105
E106, Pump system 10 107
E109, EPS AC0 10 110
Trouble shooting table – battery 10 133
Battery stops 10 133
Wiring diagram 10 134
Appendix 1, Menu tree 10 135
Edition 2013B
Speed control and brake systems
Speed controller 11 3
Dismantling the speed and brake controls 11 3
Inspection and adjustment of the speed control 11 3
Gill sensor 11 4
Calibrating the speed controller (Gill sensor) 11 4
List of contents
SERVICE MANUAL U AC POWER PLUS
Calibrating the speed controls (SLOAN) 11 6
Brake Pedal 11 8
Adjusting and checking the brake pedal 11 9
Calibrating the UFS brake pedal 11 11
Left foot switch 11 14
Dismantling, assembling the left foot switch 11 14
Adjusting the left foot switch 11 15
Preventive maintenance 11 15
Electric brake 11 16
Electric brake, 1 disc (–2003w01) 11 16
Electric brake (2003w02–) 11 17
Trouble shooting 11 19
The brake does not release 11 19
Edition 2013A
Extra accessories
Level selector 12 3
Setting the switch level system 12 4
Height preselection 12 4
Operating height preselection 12 4
Pulse height preset 12 5
Operation 12 5
Checking settings 12 6
Example of use 12 6
Height measurement instrument 12 8
General 12 8
Technology 12 8
Settings 12 8
Programming 12 8
Setting the offset value 12 8
Protecting the preset value 12 9
Setting COEFF 12 9
Setting dECPt 12 9
Final test 12 9
Sensor 12 9
List of contents
SERVICE MANUAL U AC POWER PLUS
Adjusting the sensor 12 9
Height indication on the display 12 10
Cab 12 11
Heating and ventilation 12 11
Ergologic 12 14
Electric calibration 12 14
Mechanical adjustment of the lifting/lowering potentiometer 12 15
Semi-automatic tilt centring 12 16
Semi-automatic side-shift centring 12 17
Stability Support System, S3 12 18
Identification 12 18
Functionality 12 18
Drive Speed 12 19
Hydraulic functions 12 21
Technical description 12 21
S3 option 2 (S3-2), weight indication 12 22
Functionality 12 22
Technical description 12 22
Calibration 12 22
Truck Remote ACcess, TRAC 12 25
Antistatic chain 12 26
1 1 Introduction 1 3
1 1 1 Service Manual 1 3
1 1 2 The trucks 1 3
1 2 Structure of the Manual 1 4
1 2 1 Symbol key 1 4
1 2 2 History 1 4
1 3 Safety 1 6
1 3 1 Lifting points 1 6
1 3 2 Safety instructions 1 7
1 3 3 Truck modification 1 7
1 3 4 Environmentally hazardous waste – Environment 1 8
1 3 5 Operation 1 8
1 3 6 Trouble shooting 1 9
1 4 Designations 1 10
1 4 1 Truck types 1 10
1 5 Measurements 1 15
1 5 1 Dimensional descriptions UNS, UHS 1 15
1 5 2 Dimensional descriptions UFS 1 16
1 5 3 Dimensional descriptions USS 1 17
1 5 4 Dimensional descriptions URF 1 18
1 6 Component specification 1 19
1 6 1 Traction motor 1 19
1 6 2 Electric brake 1 19
1 6 3 Gearbox 1 19
1 6 4 Hydraulic unit 1 20
1 6 5 Control system for motor 1 20
1 6 6 Battery 1 21
SERVICE MANUAL U AC POWER PLUS
1 6 7 Servo motor 1 21
1 6 8 “Fly By Wire” servo control unit 1 21
1 6 9 Steering servo unit EPS 2001 1 21
1 7 Tightening torque 1 22
1 7 1 Conversion table torque 1 22
1 7 2 Screw types and tensile grades 1 23
1 8 Recommended oil and grease types 1 25
1 9 Code explanations 1 28
1 9 1 Machine colours according to NCS 1 28
1 9 2 Colour codes for Atlet’s wiring diagrams 1 28
1 9 3 Designations for electrical components 1 29
1 9 4 Units 1 30

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