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
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.
The trucks :
- The new generation of reach trucks in the U** AC Power Plus range have a new exterior design and new content. The trucks have been developed with the focus set on the driver’s working environment and a completely new driver environment with improved ergonomics.
- New time saving solutions reduce the time required for servicing. The drive motor, hydraulic motor and all service points are easily accessible. The trucks are also equipped with truck computer,which facilitate trouble shooting.
Manual structure :
The manual is arranged according to the same principles as the Atlet’s spare part catalogues, i.e. a system consists of 12 tabs, where tabs 4 – 12 contains information limited to a specific part of the truck. For example, Masts (section 6) and Hydraulic System (section 8). Tabs 1 – 3 in this manual contain more comprehensive information regarding technical data, general service instructions and tools. For specific problems or information about procedures, look in the list of contents for the correct section.
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
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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]
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