U - AC Power Plus,Manual No 005953_A
April 19, 2017 | Author: Pedro Carvalho | Category: N/A
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Description
Service Manual U - AC Power Plus Manual Nr: 005954 Edition: A
Approved 2000-11-10 by:
Johan Rydenskog Product Responsible
Bo Bidhagen Technical Documentation
Atlet AB is certified according to ISO 9001
1:A
General information and technical data
2:A
Special tools
3:A
Service
4:A
Chassis
5:A
Drive unit
6:A
Mast
7:A
Steering
8:A
Hydraulic system
9:A
Lift cylinder
10:A
Electrical system
11:A
Drive and brake system
12:A
Options
Service Manual U - AC Power Plus Manual No: 005953 Section:1 Issue: A
1 General information and technical data .....................................1.3 1.1 General information ......................................................................................................................1.3 1.2 How to use the manual ..................................................................................................................1.3 1.2.1 Symbol key ........................................................................................................................1.3 1.3 Safety.............................................................................................................................................1.4 1.3.1 Lifting points ......................................................................................................................1.4 1.3.2 Safety instructions ..............................................................................................................1.5 1.3.3 Environment .......................................................................................................................1.5 1.3.4 Handling .............................................................................................................................1.5 1.3.5 Trouble shooting ................................................................................................................1.6 1.4 Type designations..........................................................................................................................1.6 1.5 Component specification ...............................................................................................................1.8 1.5.1 Drive motor ........................................................................................................................1.8 1.5.2 Electric brakes ....................................................................................................................1.8 1.5.3 Gearbox ..............................................................................................................................1.8 1.5.4 Hydraulic unit ....................................................................................................................1.8 1.5.5 Control system for motors .................................................................................................1.9 1.5.6 Battery ................................................................................................................................1.9 1.5.7 Servo motor ........................................................................................................................1.9 1.5.8 Steering servo unit ACC ....................................................................................................1.9 1.6 Tightening torque .......................................................................................................................1.10 1.6.1 Conversion table torque ...................................................................................................1.10 1.6.2 Bolt types and tensile grades ...........................................................................................1.11 1.7 Lubrication ..................................................................................................................................1.12 1.7.1 Lubrication chart U*S ......................................................................................................1.12 1.7.2 Symbol key lubrication chart ...........................................................................................1.13 1.8 Recommended oil and grease......................................................................................................1.14 1.9 Recommended replacement ........................................................................................................1.15 1.10 Machine colours according to NCS...........................................................................................1.15 1.11 Colour codes for Atlet's wiring diagrams..................................................................................1.15 1.12 Designations for electrical components ....................................................................................1.16 First letter ...........................................................................................................................1.16 Second letter.......................................................................................................................1.16 1.13 Units ..........................................................................................................................................1.17
ATLET SERVICE MANUAL U - AC Power Plus
1.1
1.2
ATLET SERVICE MANUAL U - AC Power Plus
1
General information and technical data
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 January 2000. You may find contradictions in the manual compared with the models supplied due to optional designs and the like. Warning! If the truck is rebuilt after delivery or supplemented in such a manner that safety may be affected, ATLET AB or its representative should be contacted. 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. Subject to alteration. 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.
1.1
General information
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.
1.2
How to use the manual
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.
1.2.1
Symbol key Warning! Used with risk of personal injury.
) "
IMPORTANT! Used with the risk of damage to the machine. Note! Used for general observation. ATLET SERVICE MANUAL U - AC Power Plus
1.3
1.3
Safety
1.3.1
Lifting points
A
B
SM 172.1
Figure 1.1
The picture above shows where the permitted lifting points are located on the truck. The lifting points are marked with a decal representing a lifting hook. When lifting just the mast, the lifting hole in the outer mast must be used (point A). When lifting the entire truck use the lifting points on the chassis support frame (point B) 1.4
ATLET SERVICE MANUAL U - AC Power Plus
Warning! The machine must never be lifted from the driver’s overhead guard.
1.3.2
Safety instructions
•
When the truck is lifted using a jack, make sure you secure it using blocks. The truck must not rest on the jack, while work is carried out.
•
Ensure that straps, wires or chains have a sufficient lifting capacity before use.
•
Pull out the plug and wait 2 minutes before starting work on the electrical system. See the warning sign.
•
Ensure the drive wheel runs free of the floor before trouble shooting.
•
When dismantling hydraulic components, the system should not be pressurised, e.g. the pump motor shutoff and the forks down, .
•
The battery plug must always be disconnected and all connections to the truck computer unit, servo unit, and regulators (applies to all electronic units) must be disconnected during all welding work. Once the welding work has been completed the connector must first be connected to the truck computer unit, then connect the battery plug.
•
Persons must not be in the area between the mast and the machine housing if the battery plug is connected. Warning! Operation of the electrical emergency switch does not make the truck completely dead.
1.3.3
Environment
Waste material that arises due to repair, maintenance or cleaning should be collected and disposed of in accordance with the directives of each country. Such work may only be carried out in areas intended for this purpose. Take care of the environment!
1.3.4
Handling
•
Ensure all essential tools are close at hand before starting work.
•
Check colour codes and for damage to cables and connectors before the cable harness or other electrical components are disconnected.
•
When complex assemblies are repaired and need to be dismantled ensure that you have good control of the different component parts so that confusion is avoided.
•
When repairing or maintaining sensitive components ensure you use clean tools and work on a clean work surface.
•
Dismantle, inspect and adjust components according to the prescribed routines. See respective sections for detailed information.
•
Ensure gaskets, O-rings, etc. are replaced with new parts each time they are dismantled.
•
Always use Atlet’s original spare parts. Those persons using non approved spare parts accept, without exception, full responsibility for any damage. Hydraulic hoses should be kept so that they do not age too quickly.
ATLET SERVICE MANUAL U - AC Power Plus
1.5
•
Use the screws and bolts stated in the spare parts catalogue. Tighten according to instructions. In those cases where the tightening torque is not stated refer to the table of standard tightening torques, see section 1.6 Tightening torque
1.3.5
Trouble shooting
When you suspect a faulty component, do not replace it immediately. First check the surrounding equipment and carry out complete trouble shooting routines. Be sure of the reason for the fault before replacing components.
1.4
Type designations
Truck type
UNS, UHS
Designations:
U = Reach truck
N = Normal
RF = Rotating forks
S = Standard
H = High lift
TF = Telescope forks
S = Narrow (second letter)
F = Four way
E = Ergonomics
C = Compact
Load capacity: UNS / UHS: 1400, 1600, 2000 kg Mast type:
Battery types:
UNS
140, 160, 141, 200 DTFV
UHS
141, 200 DTFV
UNS / UHS:
R, X, M
R = Reach M = Motor powered battery rollers X = Battery on rollers
Battery size:
UNS:
C, E, F, G
UHS:
E, F, G
Battery
C:
Approx. 450 Ah.
capacity:
E:
Approx. 600 Ah.
F:
Approx. 750 Ah.
G:
Approx. 900 Ah.
1.6
ATLET SERVICE MANUAL U - AC Power Plus
Combina-
140 UNS, 160 UNS, 141 UNS, 200 UNS.
tions:
141 UHS, 200 UHS.
Type designations (example):
UNS / 140 DTFV R E 540 Truck type: UNS
Loading capacity / 10
Mast type
DTF
Clear view mast Battery type Battery size Lift height H4 cm SM 173.1
Figure 1.2
Available battery combinations UNS 140 UNS 160 UNS 141 UNS 200 UHS 141 UHS 200
RC X X X
RE X X X X X X
RF X X X X X
RG
X X
XC X X X
XE X X X X X X
XF
XG
XFM
X X X X X
X
X
X
X
ATLET SERVICE MANUAL U - AC Power Plus
1.7
1.5
Component specification
1.5.1
Drive motor
(Also see section 5, Drive motor) Make
Elmo
Output
7.5 kW, S3 60% at 2500
1.5.2
Electric brakes
UNS / UHS (Also see section 5, Electric brakes) Make
Lenze (1 stage 1 disc)
Braking torque
125 Nm
1.5.3
Gearbox
(Also see section 5, Gearbox) Make
Kordel
Gear ratio
18,37:1
Oil volume
3.5 l
Oil type
See section 1.8
1.5.4
Hydraulic unit
(Also see section 8, Hydraulic unit) Motor/Pump Make
Elmo / Eckerle
Output
14 kW, S3 15% at 2300
Max pressure
175 bar
Working pressure
150-165 bar
Flow
13.3 cm3/r
Tank volume
Max 34 l
Oil type normal environment
1.8
See section 1.9
ATLET SERVICE MANUAL U - AC Power Plus
1.5.5
Control system for motors
Make
Inmotion
Type
83R09027A
Voltage
48 V
1.5.6
Battery
Voltage
48 V
Capacity area UN / UH / UFS
300 - 900 Ah
Capacity area URF/UTF
900 Ah
Capacity area USS
300 - 750 Ah
1.5.7
Servo motor
Make
Kordel
Voltage
48 V
1.5.8
Steering servo unit ACC
Make
Inmotion
Voltage
48 V
Current capacity
21 A
Fly by Wire
ATLET SERVICE MANUAL U - AC Power Plus
1.9
1.6
Tightening torque DIM 4.6 Nm
Tensile grade 8.8 10.9 Nm Nm
12.9 Nm
M4 M5 M6 M8
1.1 2.2 3.7 8.9
2.9 5.7 9.8 24
4.0 8.1 14 33
4.9 9.7 17 40
M10 M12 M14 M16 M18 M20
17 30 48 74 103 144
47 81 128 197 275 385
65 114 181 277 386 541
79 136 217 333 463 649
The tightening torque values in the table above are standard values. In some cases specific tightening torque values are stated in respective tabs. If no tightening torque value is stated in the service instructions the values shown in the table above apply.
1.6.1
1.10
Conversion table torque Newton metres (Nm)
Kilo pond metre (kpm)
Pound force inch (lbg x in)
Pound force foot (lbf x ft)
1 9.81 0.11 1.36
0.10 1 0.01 0,14
8.85 86.8 1 12
0.74 7.23 0.08 1
ATLET SERVICE MANUAL U - AC Power Plus
1.6.2
Bolt types and tensile grades Bolt type
Designation
Tensile grade
M6S
Hexagon bolt
8.8 10.9
8.8
8.8 10.9 12.9
MC6S
Hexagon hole bolt
MF6S
Hexagon hole bolt, countersunk
10.9
MCS
Slotted screw
4.6
MVBF
Square raised head
4.6
8.8
10.0
SM 166.1
Marking and the manufacturer's trademark as well as tensile grade are compulsory for bolts with a thread diameter from 5 mm and in tensile grades according to the table above. Marking only takes place when the shape of the product permits this.
8.8 8.8
12.9 12.9 SM 031.1
Figure 1.3
ATLET SERVICE MANUAL U - AC Power Plus
1.11
1.7
Lubrication
1.7.1
Lubrication chart U*S
H A
I
B
J
C K
D
L F M
N O
G
P
Service Årlig Service SM 174.1
Figure 1.4
1.12
ATLET SERVICE MANUAL U - AC Power Plus
1.7.2
Symbol key lubrication chart Symbol
Key
Symbol
Key
Hydraulic oil
Hydraulic oil and filter, replace
Gearbox oil
Gearbox oil, replace
Grease
Chain spray
Chain spray / oil
Only cold storage design
Teflon paste Applicable in general for the symbols: Unfilled symbol - Check lubrication Filled symbol - Replace
A.
Mast damping
J.
Chain pulley
B.
Mast profile, roller surfaces and slide surfaces
L.
Hydraulic tank
C.
Fork carriage, slide surfaces for fork carriage
M.
Hinge
D.
Fork carriage, thrust rollers
N.
Torsion ring bearing
E.
Steering transmission chain
O.
Gearbox
F.
Battery lock, slide surfaces and springs P.
G.
Mast shift and tilt cylinders
H.
Mast and carriage bearing, thrust rollers
I.
Lift chains, all lift chains in the mast.
Accelerator and brake controls, slide surfaces and springs
Chains fork carriage TF
)
IMPORTANT! All torsion springs in the machine should be lubricated during each service.
ATLET SERVICE MANUAL U - AC Power Plus
1.13
1.8
Recommended oil and grease Brand
Gearbox oil According to APIclass GL-5
Hydraulic oil According to VG class 32, 15
Normal
Cold storage
Normal (32)
Cold store (15)
Normal
BP
BP Energear FE 80 W140
BP Energear 75W-140 EP-S
Bartran SHF-S 32 Bartran HV32
BP Energol SHF-Lt 15
Energrease LS EP2
Mobil
Mobilube SHC 80W-140
Mobilub e DTE 13 M SHC 75W-140
DTE 11M
Mobilplex 48
Shell
Spirax HD Hypoid oil 85W-140 75W-140
Tellus oil T32 or: TX32
Tellus oil T 15
Alvania G2 or: Retinax LX2
Exxon / Statoil
Gearway G5 85W-140
Syntol 75W-140
Hydraway HV 32
Texaco
Geartex EPC 80W-140
_
Rando oil HDZ 32
Rando oil HDZ 15
Multifak EP2
Castrol
Hypoy C 80W-140
_
Hyspin AWH 32
Hydraulic OM 15 or: Hyspin AWH15
Speerol SW2 or: AP2
Gleitmo
Grease, bearings, mast, seat, etc.
Tergoseat bushing
Side-shift
Teflon paste
Molybd. Alloy 882EP HVY
Cold storage
Univis J 26 Uniway Li 42 or: Li62
Gleitmo 805
Others
The side-shift’s slide surfaces should be lubricated using open gear grease.
)
IMPORTANT! Do not mix different lubricants - definitely not synthetic oil with mineral oil!
1.14
ATLET SERVICE MANUAL U - AC Power Plus
1.9
Recommended replacement
Hoses should be replaced after 5 years as these are perishable. Hydraulic oil should be replaced after 1 year or 1000 operating hours
1.10
1.11
"
Machine colours according to NCS Machine colour
Notation
Yellow Medium grey Dark grey
NCS 0070-Y20R NCS 7000 NCS 8000
Colour codes for Atlet's wiring diagrams Code
Cable colour
BE BL BN GN GR O P R SB VO W Y
Beige Blue Brown Green Grey Orange Pink Red Black Violet White Yellow
Note! Twin coloured cables are shown with both colour codes separated by a slash. For example, Blue and yellow cables are defined with the colour code BL/Y.
ATLET SERVICE MANUAL U - AC Power Plus
1.15
1.12
Designations for electrical components
First letter Code Designation A
Component or function. without its own letter below
C
Contactor
D
Diode
E
Electronic component
F
Fuse
G
Battery
I
Indicator
K
Relay
L/H Lamp unit M
Motor
P/X Plug R
Resistor
S
Switch
T
Terminal
W
Warning unit with sound
Y
Brakes
Second letter Code Designation B
Brakes
C
Control system
E
Emergency function
F
Forward
H
Hour
K
Key
L
Lower
M
Manoeuvre
P
Pump
R
Reverse
S
Speed
Example SL = Switch for Lowering function 1.16
ATLET SERVICE MANUAL U - AC Power Plus
1.13
Units Abbreviation
Key
A V V/A W Nm k M
Ampere Volt Ohm Watt Newton metre kilo (=1000) Mega (=1 000 000)
ATLET SERVICE MANUAL U - AC Power Plus
1.17
1.18
ATLET SERVICE MANUAL U - AC Power Plus
Service Manual U - AC Power Plus Manual No: 005953 Section:2 Issue: A
2 Special tools....................................................................................2.3 2.1 List of tools....................................................................................................................................2.3
ATLET SERVICE MANUAL U - AC Power Plus
2.1
2.2
ATLET SERVICE MANUAL U - AC Power Plus
2
Special tools
2.1
List of tools
Tool
Part number P/N
Communications cable, truck computer (ATC) Axle puller for load wheel Lifting eye M8 (Lift motor) Lifting eye M12 (Drive motor) Hand spray (for Kryotox-grease) Insulation test instrument Lubrication Printer
110360 001210 015101 015100 110782 111111 112268 110668
ATLET SERVICE MANUAL U - AC Power Plus
2.3
2.4
ATLET SERVICE MANUAL U - AC Power Plus
Service Manual U - AC Power Plus Manual No: 005953 Section:3 Issue: A
3 Service ............................................................................................3.3 3.1 Service inspection list....................................................................................................................3.3 3.2 Code explanation ...........................................................................................................................3.9
ATLET SERVICE MANUAL U - AC Power Plus
3.1
3.2
ATLET SERVICE MANUAL U - AC Power Plus
3
Service
Service should be carried out regularly two times a year with normal truck usage, i.e. 1000 operating hours per year. The planned service (500 h) includes stages such as driving tests, operating tests, filter replacement, oil changing and replacement of carbon brushes, etc. Servicing takes place at different time intervals depending on the truck’s number of operating hours. The service interval should be more frequent if the truck works in extreme conditions or in rugged environments.
3.1
Service inspection list
A complete operations test must be performed before the inspection. Faulty functions must be rectified before the inspection.
)
IMPORTANT! The truck must be cleaned, springs and all moving parts (axles) must be lubricated with every service inspection. All mountings on the driver’s guard, battery partition, side plates and drive unit must be tightened with every service inspection.
Special attention should be made to the inspection of the electrical emergency stop device. If contactor tips on the contactors appear to be worn with a visual inspection these should be replaced as a preventive measure. Applies to contactors K10, K11 and K12.
)
IMPORTANT! The contactor tips should always be replaced and the entire device operations tested if the emergency stop has been used in an emergency situation.
For further information about procedures for inspections, repairs and replacement refer to respective sections. See the list of contents. Planned service inspections take place according to the following points:
ATLET SERVICE MANUAL U - AC Power Plus
3.3
Chassis Inspection points
Symptom
Signs/Decals Doors, panels
None, unreadable Mounting damage Driver seat Mounting, damage, lubrication * Overhead guard Mounting Deformation, cracks, other damage Load wheel Damage, wear Noise Mounting Battery stop, Damage, Battery rollers, mounting, Battery lock lubrication * Rubber mats, compartment, Chassis, general
Damage Mounting Appearance Damage Loose bolts
Inspection
Service code
Visual Visual, tools,
1024, 1101 1005, 1102 1032 * 1107, 1034 * 1035
Visual, tools, Visual, tools, Visual, tools,
Visual Listen, tool Visual, tools,
1051, 1108
Visual, tools,
1014, 1013 * 1105, 1058
Visual Visual, tools, Visual Visual Tool
* See lubrication chart in section 1
3.4
ATLET SERVICE MANUAL U - AC Power Plus
1033, 1112 *
Frame Inspection points
Symptom
Lift chains #
Chain adjustment Lubrication * Damage, chain Damage, chain bolt and chain bolt mounting Forks # Weld damage Wear Angle Mast Cracks/Weld damage Mast dampening Lubrication * Play damage, wear to rollers Angle, parallel deformation Mounting rollers Reach carriage Crack formation/ welded joints Lubrication Play damage, wear to rollers Deformation Fork carriage Cracks/Weld damage Wear, damage
Inspection
Service code
By hand Visual, tools, Visual Visual
2008
Visual Visual Visual Visual, tools,
2026, 2107
Operating test Visual, tools, Visual, tools, operating test Visual Visual, tools, Visual/tools,
2101, 2103
*
Visual, tools, Visual, tools, operating test Visual Visual, tools,
2007, 2004 2033
Visual
* See lubrication chart in section 1 # Fork tests and chain tests must be carried out at least every 1000 operating hours, see section 6.
ATLET SERVICE MANUAL U - AC Power Plus
3.5
Drive unit Inspection points Gearbox * Drive axle Gear
Drive motor
Symptom
Inspection
Service code
Oil level Noise Noise Oil leakage Function, noise
Visual, filling Listen, tool Listen, tool Visual, tools, Listen, tool
3101, 3006 3104 3106
Cable connections Drive wheel Noise Damage, wear Mounting, play Turning bearing Noise, lubrication *
Visual, tools, Listen, tool Visual Visual, tools, Listen, lubricate
7027, 7112, 7104 3005, 3102, 3002 3103
* See lubrication chart in section 1
Steering Symptom Inspection
Inspection points Gear Servo motor Mini/Midi steering wheel Tachometer
3.6
Noise Mounting Carbon brush wear Mounting Damage, wear
Listen, lubricate Visual, tools, Visual, tools, Visual, tools, Visual, function test tools
ATLET SERVICE MANUAL U - AC Power Plus
Service code 4009 4014 4013
Brakes Inspection points
Symptom
Inspection
Service code
Braking force #
Operating fault
5012
Braking effect Parking brake Brake disc
Braking distance Operating fault
Function test tools Measure, tool Function test tools Visual, tools,
Wear
5014 5104
# Also see section 11.
Inspection points
Hydraulic system Symptom Inspection
Hydraulic tank
Oil level Visual, filling Damage, leakage, Visual, cleaning contamination Air, oil filter Visual, replacement blocked # Cylinders Function Function test, stop watch Damage Visual, replacement Leakage Visual, tools, replace Cracks/ Visual, tools, Weld damage replacement Damage, chain Visual, tools, bracket Hoses Leakage, damage Visual, tools, Mounting Visual, tools, Nipples Leakage Visual, tools, Pump motor Function, noise Listen, tool Cable connections Visual, tools, Hydraulic pump Leakage Visual, tools, Damage Visual, tools, Noise Listen Proportional Operating fault Test of lever function valve, on/off Operating fault Calibration of levers valve Leakage Visual, tools,
Service code 6012, 6102
6017, 6001
6106 6019
6109
6009
# Filter replacement at the latest every 1000 operating hours or if necessary (when it is dirty). For more information regarding the hydraulic system, also see section 8 and lift cylinders section 9.
ATLET SERVICE MANUAL U - AC Power Plus
3.7
Electrical system Symptom Inspection
Inspection points Cables, switch Connectors
Battery
AC regulator Cable harness Horn Speed controller and brake pedal Level selector Speed switch Fuses
Damage operating faults, not clean Operating fault Cable breakage Contactor strip Charging error Low acid level Low acid weight Damage
Visual, tools, replace Visual, tools, replace Visual, tools, Visual, tools, Tool Tools, Tools, Visual
Low capacity after charging Battery plug, operating fault Cable breakage
Tools, DC voltmeter Operating test, tools Visual, tools,
Damage, breakage Operating fault Mounting Operating fault Operating fault Operating fault Operating fault
Visual, tools, Function test Visual, tools, Function test Calibration Function test Function test
7104 7014 7106
Blown
Visual, measure, replace Visual, contact surfaces Visual, tools, Visual Function test tools Visual, tools, Function test Function test service functions Visual Visual, tools,
7103
Battery plug
Operating fault
Video camera
Mounting Damage Operating fault
Truck computer: Display, Keyboard, Control unit
Damage, wear Operating fault Mounting Read error log# Incorrect display of measurement values
3.8
Service code
ATLET SERVICE MANUAL U - AC Power Plus
7107
7032
7025
7034 7035
7008 7037
7203, 7012 7202, 7004
Electrical system Symptom Inspection
Inspection points Cooling fans
Function #
Service code
Function test
# Read error log and temperature log.
3.2
Code explanation Chassis Code
Designation
Check
1112
Optional equipment
1005 1024
Doors Machine plate
1032
Panels
1033
Paint
1058 1035
Rubber strips Overhead guard
1107
Seat
1051 1108
Rail wheel Rail wheel bearing
1013
Battery locking
User Manual, hydrometer and battery water bottle. Bolts should be tightened. Mounting, text shall correspond with machine type, symbols and warning decals should be fitted. Mounted using bolts and clips as well as bonded parts. Scraping of paint and attachment/ scraping of decals. Secured with glue or screws. Cracks in welds, collision damage tightening of bolts. Setting, tilt function, load and angle adjustment. Chassis mounting. Rubber wheel wear. Dirt. Friction free movement, remove string, plastic bands, etc. that has collected. Mounting and lock function.
Reference.
1.9 1.4
4.3 1.11
1.9, 4.1 4.5 4.2.2 4.2.2 4.2
Mast Code
Designation
Check
Refer to
2008
Lift chains
6.6.2
2026
Forks
2101
Mast play
2007 2033
Rollers in fork carriage Side Shift
Equally adjusted, bolts locked, rust, wear, chain pulley locked. Locking device, cracks, damage, parallelism. Check the max. play. Lubricate sliding surfaces Washers. Lubrication of roller surfaces. Mounting in fork carriage.
ATLET SERVICE MANUAL U - AC Power Plus
6.4.3 6.2 6.4
3.9
Mast Code
Designation
Check
Refer to
2103
Mast rollers
Washers. Lubrication of roller surfaces.
6
Drive unit Code
Designation
Check
Refer to
3006
Oil leakage
Leakage from axles, joints, plugs or material.
5.6
3101 3005 3106 3103 3104 3002 3102
Oil level Drive wheel bolts Gears Sliding bearing Drive axle Drive wheel Noise
Oil level. Oil change. Mounting Gear ratio Noise, need of lubrication Tightening of nuts. Wear, damage, clean. Gears, nut tightening.
1.7.3, 5.4.1 1.9 1.7.3 1.10 1.9, 5.6 5.7 1.9
Steering Code
Designation
Check
Refer to
4004 4009 4014 4013
Gear drive Intermediate wheel Servo motor Mini-wheel
Play, lubrication. Axle locking, lubrication Mounting, carbon brush wear Mounting, rotary motion
1.10 1.10 7.2 7.2
Brake unit Code
Designation
Check
Refer to
5012
Braking force
Braking distance.
5014 5104
Parking brake Brake disc
Operation, cable connections Friction surface > min level all round
11.2.1 11.3.4 11.5 11.4.2
Hydraulic system Code
Designation
Check
Refer to
6012 6017 6106 6001
Oil level in tank Lowering Hoses Lift cylinders
1.14 1.5, 1.6 1.15 9
6019 6109
Nipples Hydraulic pump
Oil level between min and max Check lowering speed Cracks, wear, damage Leakage by mountings, welds, wiper, piston rod Leakage Leakage between pump and motor
3.10
ATLET SERVICE MANUAL U - AC Power Plus
Hydraulic system Code
Designation
Check
Refer to
6009 6111 6102
Hydraulic valve Optional equipment Filter
Leakage between sections, connections. Leakage from connections Replacement necessary
8.5 8.1 8.1
ATLET SERVICE MANUAL U - AC Power Plus
3.11
Electrical system Code
Designation
Check
7101
Connectors
7032
Battery
7025 7104
Transistor system Cable harness
7014 7106 7012 7034
Horn Speed controller Hour meter Level selector
7035
Speed switch
7017 7103 7008 7037
Microswitch Fuses Battery connections Video equipment
7203 7202
Display Keyboard
Contact surfaces, cable connections, dust guard. Remove the contact strips if they are burnt. Acid level, charging. Note read off from the hydrometer, clean if necessary Dirt, moisture Cable connections. Cable connections, fastening, run free from sharp edges. Function Mounting and function. Read off the display The mounting and placement of the switch. Function Switch in mast, fork carriage, forks regarding creep speed. Function That they are not brittle. That cable connections are not overheating. Operation, mounting of cameras and monitors. Damage and stretching of cables in the mast. Fastening, damage. Mounting, damage, readability
7027 7112 7030
Drive motor, bearings Drive motor cables Pump motor
Noise Fastening, damage. Need of cleaning. Mounting. Need of cleaning.
Refer to
3.12
ATLET SERVICE MANUAL U - AC Power Plus
Service Manual U - AC Power Plus Manual No: 005953 Section:4 Issue: A
4 Chassis ............................................................................................4.3 4.1 Chassis, plates ...............................................................................................................................4.3 4.1.1 Dismantling, assembling the overhead guard ....................................................................4.3 4.1.2 Dismantling, assembling the overhead guard stanchion ....................................................4.4 4.2 Chassis, machine housing components ........................................................................................4.4 4.2.1 Dismantling, assembling the rail wheel .............................................................................4.4 4.2.2 Adjusting the door .............................................................................................................4.5 4.2.3 Battery lock, battery type R ................................................................................................4.6 4.3 Panels.............................................................................................................................................4.7 4.3.1 Dismantling, assembling of the panels ..............................................................................4.7 4.4 Adjustable arm rest U*S................................................................................................................4.8 4.4.1 Dismantling, assembling the arm rest. ...............................................................................4.8 4.5 Driver seat U*S .............................................................................................................................4.9 4.5.1 Adjusting the dampening ...................................................................................................4.9 4.5.2 Adjusting the lumbar support ............................................................................................4.9 4.5.3 Adjusting the arm rest ........................................................................................................4.9 4.5.4 Adjusting the seat forwards/backwards .............................................................................4.9 4.5.5 Vertically adjusting the front edge of the seat cushion ......................................................4.9
ATLET SERVICE MANUAL U - AC Power Plus
4.1
4.2
ATLET SERVICE MANUAL U - AC Power Plus
4
Chassis
The chassis on trucks in the U-range are built-up of modules. The different chassis parts are mounted on the chassis base.
4.1
Chassis, plates
Battery wall to bottom frame, pos 8 (M10) is tightened to 65 Nm. 2
The side plates to bottom frame, pos 21 (M12) are tightened to 114 Nm.
1
3
19
2
The motor bed pos 28 and 29, are tightened to 320 Nm.
15
3
5
Pos 14, M10 nuts on welded studs are tightened to a torque of 20 Nm.
"
4
7
14 12
3 4
Note! Other bolts and screws are tightened to the torque stated in the table in section 1.
20
21
1413
22
8 9
23
6 10
)
3
11
12
IMPORTANT! All bolted joints for pos. 1, 5, 6, 7, 15, 19, 31 and 37 shall be retightened as a part of the routine service.
24
29
13
28
27
26
30 31
32
37 33 36
A 281.1
35
34
Figure 4.1
4.1.1
Dismantling, assembling the overhead guard
Bolt pos 2, Figure 4.1, which screws into the overhead guard support should be assembled from above. Nuts are fitted from below. The tightening torque for the nut is 81 Nm.
ATLET SERVICE MANUAL U - AC Power Plus
4.3
4.1.2
Dismantling, assembling the overhead guard support
Bolts securing the overhead guard stanchion to the side plate are assembled from above. Nuts are fitted from below. The tightening torque for the nut is 81 Nm.
"
Note! Other bolts and screws are tightened to the torque stated in the table in section 1.
4.2
Chassis, machine housing components
4.2.1
Dismantling, assembling the load wheel
•
Jack up the rail wheel and support the chassis.
•
Remove the circlip, pos 22.
•
Push out the axle, pos 25.
•
Remove the old wheel, pos 24.
•
Fit the new wheel with bearing, pos 23, and the load wheel tube, pos 27, and the circlip, pos 26, already fitted.
•
Insert the axle, pos 25. Lock in position using the circlip, pos 22.
23
24 23
26
26
27 25 PA 286.1
22 Figure 4.2
4.4
ATLET SERVICE MANUAL U - AC Power Plus
4.2.2
Adjusting the door
The door hinge is adjustable so that the door can be opened and closed with a good fit against the chassis. •
Adjust the height of the door using the screws at the end of the hinge, pos 1. The top edge of the door, towards the hinge side, should protrude a little above the edge of the chassis.
1 2 3
Adjusting the fit of the door against the chassis: •
Loosen the screw, pos 18, a few turns.
•
Counter hold using an open ended spanner on the eccentric cam, pos 16.
•
Loosen the screw, pos 15.
16
•
Turn the eccentric cam to adjust the fit of the door, lock the eccentric cam using screw, pos 15. Check and readjust, if necessary.
17
•
Lubricate with oil or chain spray.
•
Tighten the screw, pos 18.
15
18 3 2 1 Figure 4.3
ATLET SERVICE MANUAL U - AC Power Plus
4.5
4.2.3
Battery lock, battery type R
1
Press down the “up arrow” on the keyboard at the same time as the control “reach in” is activated.
2
Press down the shaft, pos 2, which releases the battery catch.
3
Release the “arrow up” key.
4
Keep the pedal pressed down and activate the control for “reach out”.
5
To refit the battery again: Actuate the control for “reach in” until it stops. Press the ⇑ key and continue to actuate the control for “reach in” until the battery is locked.
1 2
SM 177.1
Figure 4.4
4.6
ATLET SERVICE MANUAL U - AC Power Plus
4.3
Panels
The recyclable panels are manufactured of durable, vacuum formed ABS plastic.
4.3.1
Dismantling, assembling of the panels
Loosen the two bolts holding the arm rest. Dismantle the panels using a 3 mm allen key. Clean the panels using a soapy water solution. White impact marks may appear with minor damage. These can be removed by carefully heating using a hot air gun.
1
5
6
7 2
3
4
A 280.1
Figure 4.5
ATLET SERVICE MANUAL U - AC Power Plus
4.7
4.4
Adjustable arm rest U*S
4.4.1
Dismantling, assembling the arm rest.
•
The arm rest is adjusted by means of lever, pos 22. 14 17
15 57
21
18 19 28
PA 283.1 Figure 4.6
4.8
ATLET SERVICE MANUAL U - AC Power Plus
20
22
4.5
Driver seat U*S
The driver seat is fitted with adjustable gas cartridge dampening dependent on the body weight. The lumbar support can be adjusted in three positions. The arm rests can be rotated to give a comfortable working position and lifted to assist entering and alighting from the driver compartment.
4.5.1
Adjusting the dampening
The dampening is adjusted using the knob on the seat frame behind the seat back. (pos a)
a
4.5.2
Adjusting the lumbar support
d b
The lumbar support can be adjusted in three positions by using the lever on the left-hand side of the seat. (pos b)
4.5.3
Adjusting the arm rest
The arm rest can be rotated to give a comfortable working position by means of screw, pos 7. (pos d)
e c
SM 191.1
Figure 4.7
4.5.4
Adjusting the seat forwards/backwards
The seat can be moved further forward or back by using the loop under the front of the seat. (pos c)
4.5.5
Vertically adjusting the front edge of the seat cushion
The front edge of the seat cushion can be adjusted in three positions. The cushion is released by grasping the front edge and pulling it forwards. When the required height is obtained push the cushion back in its new position. (pos e)
ATLET SERVICE MANUAL U - AC Power Plus
4.9
4.10
ATLET SERVICE MANUAL U - AC Power Plus
Service Manual U - AC Power Plus Manual No: 005953 Section:5 Issue: A
5 Drive unit .......................................................................................5.3 5.1 Dismantling, assembling the dive unit ..........................................................................................5.3 5.2 Drive motor, general instructions .................................................................................................5.4 5.2.1 Storage of machines and motors ........................................................................................5.4 5.2.2 First service ........................................................................................................................5.4 5.2.3 Preventive maintenance .....................................................................................................5.4 5.2.4 Dismantling, assembling the motor ...................................................................................5.5 5.3 Reconditioning the motor ..............................................................................................................5.5 5.3.1 Motor bearings ...................................................................................................................5.5 5.3.2 Tighten of nuts on the pinion on the motor shaft ...............................................................5.6 5.3.3 Stator housing ....................................................................................................................5.6 5.3.4 Assembly ...........................................................................................................................5.6 5.4 Gearbox .........................................................................................................................................5.6 5.4.1 First service ........................................................................................................................5.6 5.4.2 Preventive maintenance .....................................................................................................5.6 5.4.3 Replacing the gearbox .......................................................................................................5.7 5.5 Replacing the drive axle's stuffing box .........................................................................................5.8 5.6 Replacing the drive wheel .............................................................................................................5.9 5.7 Trouble shooting chart.................................................................................................................5.10
ATLET SERVICE MANUAL U - AC Power Plus
5.1
5.2
ATLET SERVICE MANUAL U - AC Power Plus
5
Drive unit
The drive unit is mounted in an assembly containing the brakes, drive motor, gearbox and drive wheel. The steering servo motor is mounted on the same motor bed. For technical data regarding component parts, see section 1.
5.1
Dismantling, assembling the drive unit
1
Lift up the machine using a jack, see section 1 “Lift points”. Place wooden blocks under, pos 5 figure 5.1, on both sides.
2
Lower the machine so it rests on the wooden blocks. The drive wheel shall run free, about 30 mm above the floor.
3
Loosen the rear chassis/member, pos 4.
4
Loosen the cable connections to the drive motor, servo motor, electric brake and steering wheel indicator. Label the cables that are not labelled to ensure correct reassembly.
5
1 3
Fit the lifting eye, pos A, as illustrated. (pos A can be ordered from Atlet, see section 2).
6
Loosen the 8 bolts, pos 6, on the bolted joint between the motor bed/chassis.
7
Carefully lift out the drive unit from the machine, (the bearings in the motor can be damaged if you lift jerkily).
8
A
The prescribed tightening torque values and the tensile grade of the bolts must be observed when reassembling the motor bed unit in the machine housing.
2 6
4
5
5
SM 175.2
Figure 5.1
Tightening torque: 320 Nm (pos 6) Tensile grade 12.9.
"
Note! Other bolts and screws are tightened to the torque stated in the table in section 1.
ATLET SERVICE MANUAL U - AC Power Plus
5.3
5.2
Drive motor, general instructions
For further technical information regarding the drive motor, see section 1 “Technical data”. Warning! The battery plug must be removed and the machine lifted so that the drive wheel runs free of the ground when working on the motor.
5.2.1
Storage of machines and motors
Machines in storage that will not be used within a month, must be given special attention so that problems do not occur when they are to be used. Dust, dirt, condensation and moisture that occurs during large changes in temperature, as well as problems with rust and oxidisation must be prevented. Consequently motors should be protected using waxed paper or the like, as well as using a moisture absorbing material, e.g. silica gel.
5.2.2
First service
•
Check that no noise comes from the motor bearings.
•
Check that no abnormal vibrations are experienced while running.
5.2.3
Preventive maintenance
Preventive maintenance is implemented in accordance with the intervals set out in the service chart. See section 3, “Service”. However, in some cases exceptions must be made and the intervals can be shortened, depending on the conditions in customer's premises, e.g. a rugged environment with dust, high humidity levels, salt, etc. •
Listen for noise from the bearings when the motor is run. Check that it does not vibrate abnormally.
•
Blow down the motor using dry compressed air or clean using a vacuum cleaner. A special cleaning fluid P/N 122268 should be used to drive out oil and dirt, if oil has leaked from the gearbox into the motor. Finally blow dry using compressed air.
•
Check that the insulation resistance for the motor does not fall below 48 K ohm.
5.4
ATLET SERVICE MANUAL U - AC Power Plus
5.2.4
"
Dismantling, assembling the motor Note! In this case only the cables to the drive motor and electric brake need to be disconnected.
•
Remove the bolts, pos 3 figure 5.2.
•
Carefully lift out the motor, pos 2, from the gearbox so that the gears are not damaged.
•
If repairs or reconditioning of the motor are to carried out, see section 5.3 “Reconditioning the motor”.
•
Check/replace the sealing ring, pos 7.
•
Assemble in the reverse order.
3 4
2
5 6
7
8
9
SM 176.1
Figure 5.2
5.3
Reconditioning the motor
A total overhaul of the motor is recommended after 3000 to 5000 operating hours. The motor should be removed from the drive unit (see 5.1, 5.2). Now dismantle the motor so that the end shields, armature are released. Great care should be exercised because the tacho sensor is integrated in one of the bearings so that the sensor is not damaged.
5.3.1
Motor bearings
The motor bearings should always be replaced when reconditioning the motors to ensure continued reliable operation.
ATLET SERVICE MANUAL U - AC Power Plus
5.5
5.3.2
Tighten of motor shaft pinion nut
Nuts securing the motor shaftpinion must be tightened to 21-26 Nm.
5.3.3
Stator housing
The housing is cleaned using a special fluid P/N 112268 and then blown dry; after the housing has dried, make an insulation test: •
Check that the insulation is satisfactory. Measure the resistance between the coil and stator housing see section 5.2.3 Preventive maintenance If the resistance is lower the motor must be blown clean and tested again.
5.3.4
Assembly
Assemble in the reverse order.
5.4
Gearbox
For further technical information regarding the gearbox, see section 1 “Technical data”.
5.4.1
First service
The first oil change should take place after approximately 150 – 200 hours. •
Drain the oil from the gear housing. (pos 40 fig 5.4)
•
Fill with oil. Recommended oil, see section 1.
5.4.2
Preventive maintenance
•
Oil change takes place after approximately 1000 operating hours or at least once a year.
•
The steering bearing must be greased at least once a year. If steam cleaning or high pressure washing has been carried out then grease bearing immediately.
5.6
ATLET SERVICE MANUAL U - AC Power Plus
5.4.3
Replacing the gearbox
•
Follow the instructions as set out in section 5.1
•
Drain the oil from the gear housing. (Pos 40 fig 5.4)
•
Remove the motor and drive wheel.
•
Remove the bolts joint, pos 5, holding the gearbox on the motor bed.
•
Lower the gearbox from the motor bed.
•
Fit the new gearbox.
"
"
5 6
Note! Do not forget to fill the gearbox with oil before starting up. The oil can be filled before the drive motor is assembled on the gearbox. To ensure the oil level is correct: open the level plug pos 34 fig 5.4 and drain off the excess oil. Note! Spent oil should be taken care of and recycled according to applicable legislation in respective countries.
9
pB 280.1
Figure 5.3
ATLET SERVICE MANUAL U - AC Power Plus
5.7
5.5 1
Replacing the drive axle's stuffing box
Lift up and secure the machine as set out in section 5.1.
2
Dismantle the drive wheel.
3
Drain the oil from the gearbox, pos 40.
4
Remove the cover, pos 36.
5
Loosen the bolts, pos 29, that hold the crown wheel halfway, and drive out the axle towards the drive wheel side.
6
7
The bolts can be unscrewed fully when the crown wheel and bearing have come free from the axle. The axle is extracted from the drive wheel side. Place the parts in the order they were dismantled to avoid confusion. Remove the roller bearing closest to the seal by knocking the axle end against a block of hard wood. Sometimes the bearing is removed more easily if you have an edged object that is inserted between the bearing's inner ring and the axle's flank. Any burrs on the axle must be removed before reassembly.
8
Carefully clean the seal bearing track in the gear housing.
9
When assembling, first mount the bearing, pos 15, in the drive wheel side of the gear case.
27
33
31 30
34 32
37 38
15 16 17
39 40
18 19 20
21 pB 202.3
Figure 5.4
10 Assemble the circlip, pos 16, and the seal, pos 17. Ensure that they sit correctly. 11 Assemble the guard, pos 19, and finally, carefully press in the drive axle, pos 21. 12 Now assemble the crown wheel and bearing. Start with the spacer. 13 Apply thread lock to the screw threads (Loctite 207) and bolt together the entire drive axle assembly with washers, pos 28, and bolts, pos 29. The bolts are tightened to the prescribed tightening torque as set out in the torque tightening table in section 1. 14 Fit the cover, pos 36. Bear-in-mind that the drainage hole should be the lowest point. Use a new gasket, pos 35. Screw in the oil drainage plug and use a new copper washer. 15 Fill with hypoid oil. See the table of recommended oil, section 1. 5.8
29
28
ATLET SERVICE MANUAL U - AC Power Plus
35
36
5.6
Replacing the drive wheel
•
Loosen the drive wheel nuts, without removing them.
•
Lift up the machine, secure with blocks.
•
Lower the machine on blocks.
•
Remove the wheel nuts and lift the wheel forward.
•
Assemble the new wheel, tighten the wheel nuts by hand.
•
Lift up and remove the blocks, lower the machine onto the floor.
•
Tighten the wheel nuts to the prescribed tightening torque 150 Nm.
ATLET SERVICE MANUAL U - AC Power Plus
5.9
5.7
Trouble shooting chart Symptom
Cause
Action
The wheel has a flapping sound The tyre has separated when driving. due to impact. The wheel squeaks continuously Bearing is damaged. when driving.
Change the wheel and check the floor for unevenness! Replace the bearing and tell the driver to remove string, plastic, etc. daily or keep the floor clean! The wheel is flat after long The wheel mass has become Offload the wheel by, e.g. running breaks, but becomes round after warm while driving and deforms the mast forwards when charging driving for a while. when parked. or change to a thinner tyre that gives better cooling! The wheel has a deformity that A “blow out” has taken place due Change the wheel! does not disappear when driving. to overheating and changed the molecular structure of the wheel mass. The wheel has transverse cracks The wheel has been heated. Small Lower the acceleration and and small bits have fallen out of cracks appear with hard reversing ramp, and change the the tyre. acceleration and reversing. wheel if necessary. The wheel has one or more small Locking of the brakes so that the Remove the objects on the floor deformities. wheel slides or loose objects on and tell the driver to brake gently! the floor that prevent the wheel from rotating. Oil on the floor. Leaking seal around the drive Replace the seal! axle. Or: Replace the drive unit! Grating noise when accelerating Defective gear wheel in the drive Check the cogs by dismantling the or with the reversing brake. unit. cover/Replace the drive unit! Grating noise when the truck is Faulty bearing in the drive motor. Dismantle and renovate the drive lifted up and the drive wheel can motor! rotate freely and the motor rotates. The truck rolls “sluggishly”. The brakes are applied. Repair and adjust the brakes! The truck rolls “sluggishly”. Drive motor has seized up. Replace the drive unit! Clicking sound when driving. Faulty wheel bearing. Replace the drive unit! Clicking sound when driving. Loose wheel. Tighten the wheel/Replace the wheel! The truck feels jerky when Hard foreign object has fastened Remove the object or replace driving. in the drive wheel. the wheel! The truck jumps at regular The wheel is oval. Change the wheel! intervals, proportional to the Check/Adjust the brakes! speed, when driving.
5.10
ATLET SERVICE MANUAL U - AC Power Plus
Service Manual U - AC Power Plus Manual No: 005953 Section:6 Issue: A
6 Mast ................................................................................................6.3 6.1 Mast 140, 160 ................................................................................................................................6.3 6.1.1 Dismantling the mast .........................................................................................................6.3 6.1.2 Adjusting the mast .............................................................................................................6.4 6.2 Mast 141, 200 ................................................................................................................................6.6 6.2.1 Dismantling the mast .........................................................................................................6.6 6.2.2 Adjusting the brass lugs .....................................................................................................6.7 6.2.3 Adjusting the mast, top ......................................................................................................6.7 6.3 Reach carriage ...............................................................................................................................6.8 6.3.1 Dismantling the reach carriage ..........................................................................................6.8 6.3.2 Adjusting the reach carriage. 141, 200 DTFV ...................................................................6.9 6.3.3 Adjusting the reach carriage 140, 160 DTFV ..................................................................6.10 6.4 Fork carriage................................................................................................................................6.11 6.4.1 Adjusting the fork carriage 140, 160 DTFV ....................................................................6.11 6.4.2 Adjusting the fork carriage, 141, 200 DTFV ...................................................................6.12 6.4.3 Dismantling, assembling the fork carriage ......................................................................6.12 6.4.4 Fork test ...........................................................................................................................6.13 6.5 Lift cylinders ...............................................................................................................................6.14 6.5.1 Adjusting, the cylinder mounting on the mast .................................................................6.14 6.6 Lift chains....................................................................................................................................6.15 6.6.1 Adjusting the lift chains ...................................................................................................6.15 6.6.2 Inspecting the lift chains ..................................................................................................6.15 6.7 Trouble shooting chart.................................................................................................................6.16 6.8 Fork side shift unit.......................................................................................................................6.16 6.8.1 Trouble shooting ..............................................................................................................6.17
ATLET SERVICE MANUAL U - AC Power Plus
6.1
6.2
ATLET SERVICE MANUAL U - AC Power Plus
6
Mast
6.1
Mast 140, 160 8
The standard mast is of the type DTFV. The masts are: • •
•
2
3 1
Double telescopic.
9 10 8
2 13
11 12
Have free lift function, i.e. the fork carriage runs to the top of the inner mast before the mast section moves upwards.
6 1 5
7
3 1
2
1
14 15 16 17
2
18
5
12 11
17 24
21
Free sight type
19 25
22 23
20
27 26 27 26
30
6.1.1 1 2
Dismantling the mast
29
41
Lower the forks to the bottom position. Secure the entire mast assembly with a lifting device.
3
Disconnect and plug the oil pipes.
4
Remove the fork carriage, see section 6.4.3 Dismantling, assembling the fork carriage.
5
Disconnect the tilt cylinders, see section 8.
6
Remove the cap on the carriage.
7
Lift off the mast.
8
Remove the lift chains and lift cylinders.
9
40
24
28 26
42 26
43
25 33 34 35
44
36 37 36 11
C 281.1
Pull out the inner mast.
10 Pull out the intermediate mast.
38 39
12
Figure 6.1
Inspecting or repairing the mast system: •
Check that the thrust rollers lie against the roller surfaces on the mast. Also check that they roll easily.
•
An operating test must be made after each measure/action on the mast system. The mast must not jam or run slowly (the mast sections may move in the wrong order) when lifting and lowering.
ATLET SERVICE MANUAL U - AC Power Plus
6.3
6.1.2
Adjusting the mast
Adjusting the play on mast 140, 160 DTFV. Adjustment is carried out by utilising the advantages of negative H4 i.e. that the inner mast is lowered so that the load rollers are accessible without the need of dismantling the mast. There are two sizes of rollers available and the possibility of shimming using 0.5 or 1 mm shims behind the load rollers to compensate for play. (The diameter is punched on each roller). 1
2
First check the play and its position before dismantling the mast. Jack up the load wheels and support securely on blocks.
sm 183.1
Figure 6.2
Lift up the forks and secure the fork carriage to the cross stay, see figure.
sm 184.1
Figure 6.3
3
Remove the lowering dampers, see figure.
sm 185.1
Figure 6.4
6.4
ATLET SERVICE MANUAL U - AC Power Plus
4
Secure a lifting device to the inner mast, see figure. Loosen the lift cylinders and secure them so that they cannot fall outwards and lower them so that they run free of the upper cylinder mountings.
1
1
sm 186.1
Figure 6.5
5
Lower the inner mast so that the mast rollers are free, see figure.
Pull off the rollers and adjust the number of shims when changing to a roller with a larger dimensions.
)
IMPORTANT! If necessary, dismantle the sensor, level measurement chain and other optional parts before the mast sections and lowered.
sm 187.1
Figure 6.6
ATLET SERVICE MANUAL U - AC Power Plus
6.5
6.2
Mast 141, 200
The standard mast is of the type DTFV. The masts are: •
Double telescopic.
•
Have free lift function, i.e. the fork carriage runs to the top of the inner mast before the mast section moves upwards.
•
Free sight type
6.2.1 1 2 3 4 5 6
Dismantling the mast
Secure the entire mast assembly with a lifting device.
7 8
9 1 2
Remove the fork carriage, see section 6.4.3 Dismantling, assembling the fork carriage.
3
7 4
5
6
12 13
12 10
10 6
8
5 4
14
15
7
2 8
7
20 21 22
8
15
24
28
25
30
27 26
Place on the floor with the outer mast downwards.
27 26
35 36
30 51
37
7
Remove the lift chains and lift cylinders.
8
Loosen the brass blocks and brass screws.
27
9
Pull out the inner mast.
26
31
32
60
34
32
29
33 26
38
42
27 28 39 40 41
43
10 Pull out the intermediate mast.
31
14
16
29
17 18 19
Lift off the mast.
1
23
10
Remove the caps on the reach carriage.
3
16 9
Remove the tilt cylinders, see section 8.
11
40
44 42
45 46
43
44
16
15
14
50 45
55 56 57
58
52 50
46
49 47
53 54
48 16
15
14
47
48
49
C 200.5
Figure 6.7
Inspecting or repairing the mast system: •
Check that the thrust rollers lie against the roller surfaces on the mast and that they roll easily.
•
Check that the thrust rollers run square to the roller surfaces. If not this will result in damage, e.g. deep grooves or chips on the mast’s roller surfaces.
•
An operating test must be made after each measure/action on the mast system. The mast must not jam or run slowly (the mast sections may move in the wrong order) when lifting and lowering.
6.6
ATLET SERVICE MANUAL U - AC Power Plus
6.2.2
Adjusting the brass blocks
Make sure the maximum play between the brass blocks and the mast section, pos 42, does not exceed 0.4 mm. The play between the thrust roller and the mast is measured using feeler gauges. The play is adjusted by inserted the required number of shims, pos 43.
42 43
44 45 46
pC 200.3
Figure 6.8
6.2.3
Adjusting the mast, top
Tilt the mast forward. The four brass bolts pos 32 at the top of the outer mast and intermediate mast, are tightened until they touch and are then loosened 90°, lock with pos 31. The four excentries, pos 4, at the top of the outer mast and intermediate mast should be adjusted so that the rollers rest against the roller surfaces. The mast sections must be parallel.
1 2
3
4
5 6
30
31
32 p2C 200.3
Figure 6.9
ATLET SERVICE MANUAL U - AC Power Plus
6.7
6.3
Reach carriage
6.3.1
Dismantling the reach carriage
1
Secure the mast assembly with a lifting device.
2
Remove the reach cylinder chassis anchor belt pos 15 fig 8.5.
3
Disconnect the mast hoses and cable connectors.
4
Remove the safety stop screws from the open end of both reach channels.
5
Pull out the reach carriage.
6
Assemble in the reverse order.
6.8
ATLET SERVICE MANUAL U - AC Power Plus
6.3.2
Adjusting the reach carriage. 141, 200 DTFV
The reach carriage’s sliding plates, pos 27, and the excentric rollers, pos 23, should be adjusted so that there is a minimum of vertical play.
6
5
35 7
Adjust the side thrust sliding plate, pos 17 by using the adjuster screws pos 32, so that the reach carriage is symmetrical and parallel with the carriage guides on the support arms. The lateral play on the reach carriage may be a maximum of 2 mm. Keep roller surfaces clean and free from debris.
6
1
5 9 10 11
8
4
2
12 13
3 30 31 29
Apply grease to the reach channel sliding surfaces.
37 38 12 13
19
36 28 27
34
33
32
42
22
21
20
26 5 23
24
25 20 22
21
5 14
15
6
6
16 17 18 39
40
41
C 210.4
Figure 6.10
ATLET SERVICE MANUAL U - AC Power Plus
6.9
6.3.3
Adjusting the reach carriage 140, 160 DTFV
The rollers on the reach carriage are of the type full roller. The lateral play is adjusted by screwing in the screws, pos 15. The lateral play may be a maximum of 2 mm, and the sliding surfaces on the support arms should be lubricated.
6 35
5
7 1
6 5 9 10 11
8
2
12 13
30
3
29 37 38
36
19
4 15
16 5
21 22
20
C 280.1
5 14 6
Figure 6.11
6.10
12 13
ATLET SERVICE MANUAL U - AC Power Plus
6
6.4
Fork carriage
Different fork arrangements are mounted on the back of the fork carriage from basic forks to complex units with side shift, fork spread and telescopic forks.
6.4.1
Adjusting the fork carriage 140, 160 DTFV
The lateral play is adjusted by adapting the number of shims behind the load rollers and by replacing the rollers, pos 16, 17.
4
7 6 6 1
4
5
11
12 3
2
13
16 17
19 33
20
C 282.1
Figure 6.12
ATLET SERVICE MANUAL U - AC Power Plus
6.11
6.4.2
Adjusting the fork carriage, 141, 200 DTFV
Side thrust rollers rest against the roller surfaces.
4
7 6
Adjust the four excentric rollers, pos 18 so that they make contact with the roller surfaces.
6 1
Warning! Tightening too much will affect the lowering speed or the mast sections will be lifted in the wrong order.
4
5
11 12 8
9 10
3
2
13
15
14
16 17 18
19 20
27 26 24 21 22
C 206.2
28 23
Figure 6.13
6.4.3
Dismantling, assembling the fork carriage
•
Lower the fork carriage on to a European pool pallet or similar.
•
Remove the lift chains.
•
Remove the stop screw on the inner mast.
•
Lift up the inner mast using a crane until the fork carriage is released.
6.12
ATLET SERVICE MANUAL U - AC Power Plus
25
6.4.4
Fork test
Seven inspection points are included in the fork test. If the forks do not pass any of the points the machine must be taken out of service. If the customer is not prepared to do this, it should be written in the report that “The forks do not comply with the demands set out in SS-ISO/ 5057". When the customer later signs the service order, he then bears responsibility for the defective forks. Straightness of the blades and Shanks: Deviation from the carrier surface and the support surface's straightness must not exceed 0.5% of the blade respective shank's length.
Marking
Difference in height between fork arm tips
SM 020.1e
Figure 6.14
L = 1150 mm, max deviation 5.75 mm. L = 950 mm, max deviation 4.75 mm. L = 800 mm, max deviation 4.00 mm. h = 492 mm, max deviation 2.46 mm. h = 464 mm, max deviation 2.32 mm.
Crack formation: Check whether the forks are cracked. Check carefully around the heel and bends. Thickness
Wear: Check the forks for wear, especially around the heel. The blade thickness must not be thinner than 90% of the original thickness. The original thickness is found by: 1
Reading the marking on old forks.
2
Measuring the blade thickness in the centre of the shank.
3
Shank Tip Thickness
Contacting Atlet for information about blade thickness.
Hook Blade Heel Length
SM 021.1e
Figure 6.15
Fork angle: The angle between the blade and the shank may be max 93 degrees. The height difference between the tips of the forks: Must not exceed 3% of the blade length. Locking device: Check that the locking device works. Labelling: The fork's marking should be clear and comprise the lifting capacity in I kg for one fork and the centre of gravity distance in mm.
ATLET SERVICE MANUAL U - AC Power Plus
6.13
6.5
Lift cylinders
6.5.1
Adjusting, the cylinder mounting on the mast
Start by lowering the mast and slackening the chains. 10
Adjust the outer cylinder mounting with the top nut, pos 10. Adjust both cylinders equally. If the movement is sufficient in the cylinder’s mounting the rollers will have contact with the mast’s runner at all lifting heights, even if the brass screws are not tightened. If the truck is fitted with a tilt function the mast should be tilted forwards. Operationally test the lifting movement. Tighten the chain and check that the rollers still make contact with the runners. The cylinder mountings should be moveable.
6.14
SM 094.2
Figure 6.16
ATLET SERVICE MANUAL U - AC Power Plus
Lift chains
6.6.1
Adjusting the lift chains
•
Place the mast vertical.
•
The inner and outer masts should be locked.
•
Adjust the two outer lift chains so that the mast hangs a little from the lift chains.
•
Adjust the centre chain so that the fork heel is: 5 (+/-2) mm from the ground.
5 2
6.6
SM 075.1
Figure 6.17
6.6.2
Inspecting the lift chains P
If the lift chains do not pass the inspection at any point the whole chain should be replaced. It is not permitted to join or re-rivet lift chains.
SM 169.1
Figure 6.18
•
Make sure the chains are clean. Make the inspection without a load.
•
Lift up the forks about 20 cm above the floor. Measure over the 25 links that run over the guide rollers, as the elongation is normally at its greatest here. Compare with the measurements below. If the chain has stretched by more than 2% it should be replaced.
3/4" 1" 1 1/4"
P
G
The truck’s lift chains should be inspected regularly, after about 1000 operating hours.
Pmeasurem ent
Measurement 25 links new chain
Max measurement 25 links 2% elongation
19.05 mm 25.40 mm 31.75 mm
476.25 mm 635.00 mm 793.75 mm
485.00 mm 658.00 mm 809.00 mm
•
Check that no pins are loose in the outer side plates.
•
Check that there are no visible cracks on any of the side plates.
•
Check that there is no signs of mechanical damage or of corrosion.
•
Check that the chains run easily over the guide cogs and do not jam.
•
Lubricate the chain with chain spray.
ATLET SERVICE MANUAL U - AC Power Plus
6.15
6.7
Trouble shooting chart Symptom
Cause
Action
Play on mast.
Worn brass lugs. Cams out of position. Brass lugs adjusted too hard. Cams adjusted too hard.
Adjust the lugs! Adjust the cams! Adjust the lugs!
The mast lowers unevenly, jumps. The mast squeaks.
6.8
Adjust the cams! No grease on the mast roller Apply grease to the roller surfaces surfaces! The rollers have rubbed Lubricate or replace the rollers! together.
Fork side shift unit
The side shift unit is supplied with the slide segments lubricated with special grease, (see section 1) (upper and lower) to ensure a good sliding capacity even after the running in period. The self-lubricating characteristics may stop in especially aggressive environment conditions. Check the sliding capacity of the side shift unit regularly. 1
2 • •
•
Check for wear to the slide segments, both the upper and lower, bearing-in-mind damage and normal wear. Replace if necessary.
2 9 10
8
1
7
Check that the cylinders do not leak, which can be because of: Scratches on the piston rod. Replace the entire cylinder! Worn external seals. Replace the seals by dismantling the piston rod bracket and circlip.
6 5
I 10.1 4 3
Figure 6.19
Worn internal seals. Replace the entire cylinder!
After 1000 hours: Clean carefully under the glide segment with its sliding surface, then grease the sliding surface.
6.16
ATLET SERVICE MANUAL U - AC Power Plus
6.8.1
Trouble shooting
Symptom No side shift
Side shift runs too slow
Cause Side shift unit deformed by collision or overloading. No play under the lower mounting blocks. Worn hydraulic hoses. Defective hydraulic pipes. Insufficient hydraulic pressure.
Hydraulic pump worn. Cylinder fault. Worn piston rod gasket Friction bush worn. Cavitation jumps – pump sucks air.
Hydraulic pump worn. Insufficient hydraulic pressure.
Irregular side shift
Air in the hydraulic system. Friction bush on the piston rod worn.
Side shift only Air in the hydraulic system. in one direction Cylinder fault. Defective valve.
"
Action Straighten! Adjust the blocks so that 1 mm of play is obtained! Replace the hoses! Correct! Increase the pressure! Check the computer’s values under the menu “VALVE PARAMETERS” Replace/repair the hydraulic pump! Replace the cylinder! Replace the cylinder! Change the bush, clean and oil! Check the trucks oil level in the tank and pump! Check that the hoses are tight! Replace/repair the hydraulic pump! Increase the pressure! Check the computer’s values under the menu “VALVE PARAMETERS” Bleed the system and check the oil level. Fill with oil if necessary! Replace the bush, clean and lubricate! Bleed the system! Replace the cylinder! Check the valve function!
Note! The cylinder is sealed and cannot be opened. There any no spare parts available.
ATLET SERVICE MANUAL U - AC Power Plus
6.17
6.18
ATLET SERVICE MANUAL U - AC Power Plus
Service Manual U - AC Power Plus Manual No: 005953 Section:7 Issue: A
7 Steering...........................................................................................7.3 7.1 Servo motor ...................................................................................................................................7.3 7.1.1 Dismantling the servo motor ..............................................................................................7.3 7.2 Electronic steering (ACC) .............................................................................................................7.4 7.2.1 Servo steering unit, functions ............................................................................................7.4 7.2.2 Settings ...............................................................................................................................7.5 7.2.3 Function control of the electric servo ................................................................................7.7 7.3 Diagnostics ....................................................................................................................................7.8 7.3.1 Outputs from the steering unit ...........................................................................................7.8 7.3.2 Control connection 13 pins ................................................................................................7.8 7.4 Trouble shooting table...................................................................................................................7.9 7.5 Settings U** ..................................................................................................................................7.9
ATLET SERVICE MANUAL U - AC Power Plus
7.1
7.2
ATLET SERVICE MANUAL U - AC Power Plus
7
Steering
The trucks in the U AC Power Plus range are equipped with an electric steering as standard and are manoeuvred using a mini wheel mounted on the left-hand armrest. The steering is divided into 3 units on the electrical side and gear transfer of power between the steering servo motor and the drive unit. The first unit, the mini wheel is a progressive steering unit. The quicker the wheel is turned the faster the movement. The second unit is a servo steering unit, which converts the steering signals to the third unit, the steering motor. There is no mechanical connection between the mini wheel and the steering wheel. The electrical section is monitored by a safety system that stops the truck if an error should occur. An error code is then shown on the display and these are then saved in the ATCII log.
7.1
Servo motor
The only adjustment of the steering system takes place electrically, the number of turns of the steering, the steering force and compensation can be set.
7.1.1
Dismantling the steering motor
1
Remove the cable connections on the steering servo motor.
2
Remove the bolts holding the steering servo motor, pos 1.
3
Lift the steering servo motor straight up.
4
Assemble in the reverse order.
1
SM 190.1 Figure 7.1
ATLET SERVICE MANUAL U - AC Power Plus
7.3
7.2
Electronic steering (ACC)
7.2.1
Servo steering unit, functions
RE1
RELAY
+
4
5 6 7 OFF
M1
M2
SW1
OPEN
1 2 3
K2
8 9 10
11 12 13
1
ON
2
LIN
1 2 3 3 4 5 6 4 7 8
K1
5
LIN ERROR ERROR
SM 033.1
Figure 7.2
Switch function (dipswitch) No. 1 2 3 4 5 6 7 8
"
Function Not used Current limit IR-compensation Sensitivity
Note! The switch is open when it is in the off position.
7.4
LED No
Indicator lamp Indicates the following when on
1 2 3 4 5
Everything OK End position End position Fault Fault
ATLET SERVICE MANUAL U - AC Power Plus
7.2.2
Settings
The current limit to the motor can be adjusted and thereby also the motor’s torque. The limit value can be set to 4 different levels through the dipswitches 2 and 3. If the torque is too low, the steering movement will be weak and slow and lag behind with rapid turning of the mini wheel. The current limit should be set so that: •
The top current does not exceed the motor’s rated data.
•
The produced torque is not greater than the strength of the mechanical components.
Servo steering unit
Dipswitch 2
Dipswitch 3
10 14 18 21
Open Open Closed Closed
Open Closed Open Closed
Min. current A
Max. current A
IR compensation affects the motor’s ability to follow the mini wheel. Compensation can be set in 4 different levels by using dipswitches 4 and 5. •
If it is set too low the motor will not follow slow wheel movement.
•
If it is too high the motor will oscillate and cause overheating.
No compensation 1/3 compensation 2/3 compensation Full compensation
Dipswitch 4 Open Open Closed Closed
ATLET SERVICE MANUAL U - AC Power Plus
Dipswitch 5 Open Closed Open Closed
7.5
The sensitivity of the tachometer affects the relation between the speed of the mini wheel and the steering motor, which in turn affects how quickly the steering reacts. The sensitivity can be set in 8 different levels using dipswitches 5, 6, 7 and 8. •
If the sensitivity is too high the steering movement can be too powerful at high speeds.
•
If the sensitivity is too low the steering will be slow.
To obtain a good sensitivity level at high and low speeds the unit is fitted with progressive steering. This means the sensitivity automatically increases with rapid steering wheel movement.
Max. sensitivity
Min. sensitivity
)
Tachometer voltage
Dipswitch 6
Dipswitch 7
Dipswitch 8
+/- 1.5 V +/-3.0 V +/-4.0 V +/-5.5 V +/-6.5 V +/-7.5 V +/-8.5 V +/-9.5 V
Closed Open Closed Open Closed Open Closed Open
Closed Closed Open Open Closed Closed Open Open
Closed Closed Closed Closed Open Open Open Open
IMPORTANT! Switch 1 not used.
7.6
ATLET SERVICE MANUAL U - AC Power Plus
7.2.3
Function check of the electric servo
1
Start the truck and check that the operation of the end stops in both directions is correct.
2
Turn the mini wheel maximum clockwise. Connect the red/black cable with the pink/black cable coming from X18’s connection closest to the servo box. Turn the steering to the centre position. After approx. 10 mm of movement on the gearbox the servo contactor should break. Check that the brakes are really applied and that it is not possible to drive the machine. If the brakes are not on and the machine can be driven then the circuit must be checked. The drive regulator E1 is fed from the servo connector E4 pin 8. Check that pin 8 is not voltage fed, if it is replace the servo box. Reset using the off-on buttons on the keyboard.
3
Brown/white cable. Perform the same procedure with the opposite switch by connecting together the red/black cable with the brown/white cable.
4
Pull apart the connector P14 (tied to the return hose on UNS). The servo contactor should break and it should be impossible to release the brake; it should also be impossible to drive the truck. Connect P14 again.
5
Pull out the motor fuse for the servo motor (F4). The servo motor should stop and it should be impossible to release the brake; it should also be impossible to drive the truck. Fit the fuse again.
6
If it is possible to release the brake after points 2, 3, 4 or 5 have been implemented, or it is possible to drive the truck, the truck must be checked carefully and not used until the fault has been rectified.
7
Finally check that drive unit does not hit the mechanical stop in the end positions.
)
IMPORTANT! Remove error codes E05 and E06 by resetting in the ATCII’s service menu “log book”.
ATLET SERVICE MANUAL U - AC Power Plus
7.7
7.3
Diagnostics
7.3.1
Outputs from the steering unit
Open collector, active = low Out 3 high and Out 12 high
Unit active
Out 3 low and Out 12 high
Faulty sensor unit
Out 3 high and Out 12 low
Fault in the steering or motor unit
Out 3 low and Out 12 low
Faulty steering unit
7.3.2
Control connection 13 pins
1.
48 V
In
Start/stop and internal supply
2
Not connected
3
Out approx. 0.2- 4.5
Error code no:1
4.
In
0V
Tachometer
5.
In
48 V
Negative direction
6.
In
(+/- 1.5 – 9.5 V
Reference voltage from tachometer
7.
Out -12V
UFS: with automatic driving of the drive wheel
8.
Out 48 V
Safety relay
9.
In
0V
Minus supply for error indication
10.
In
-12/+12V
UFS: full motor modulation with automatic turning of the drive wheel
11.
In
48 V
12.
Out
approx. 0.2- 4.5 Error code:2
13
Out
+12V
Positive direction UFS: with automatic driving of the drive wheel
Power connection 4 pins +
In
48V
Battery voltage +
-
In
0V
Battery voltage -
M1 Out
Motor connection +
M2 Out
Motor connection -
7.8
ATLET SERVICE MANUAL U - AC Power Plus
7.4
Trouble shooting table
The battery should be connected and the truck logged on.
LED 1 Green OFF ON ON ON
LED 2 LED 3 LED 4 LED 5 Red Red Red Red OFF
OFF
OFF
ON ON
ON
ON
ON
ON
ON
7.5
OFF
ON
ON
Indicates
Action
No control current OK Negative direction active Positive direction active Fault in tachometer circuit. Cable breakage, short-circuit or wrong type of tachometer Fault in the steering unit or in the motor circuit. Cable breakage or short circuit Fault in steering unit
Check supply. None None None Check the cables and connectors. If OK replace the tachometer. If still faulty, check that the right tachometer is used. Check the cables, connectors and motor brushes. If OK, replace the motor or steering unit.
Replace steering unit
Settings U**
The table shows ATLET’s factory settings: The switches are set by using a pointed tool or pen. Insert the tool in the the position marked X.
Switch 1. Not connected 2. Current limit 3. Current limit 4. Load compensation 5. Load compensation 6. Sensitivity 7. Sensitivity 8. Sensitivity
Miniwheel X
Midiwheel O
X X X X
O O O O O
X X
O X
O
ATLET SERVICE MANUAL U - AC Power Plus
7.9
7.10
ATLET SERVICE MANUAL U - AC Power Plus
Service Manual U - AC Power Plus Manual No: 005953 Section:8 Issue: A
8 Hydraulic system ...........................................................................8.3 8.2 Dismantling the pump motor.........................................................................................................8.4 8.1 Replacement of the hydraulic filter ...............................................................................................8.4 8.3 Replacing the suction hose ............................................................................................................8.5 8.4 Draining the tank ...........................................................................................................................8.5 8.5 Cylinders .......................................................................................................................................8.6 8.5.2 Dismantling the tilt cylinder from the truck ......................................................................8.6 8.5.1 Dismantling the reach cylinder from the truck ..................................................................8.6 8.5.3 Dismantling, assembling the mast shift cylinder ...............................................................8.7 8.5.4 Bleeding the mast shift cylinder ........................................................................................8.8 8.5.5 Dismantling, assembling the tilt cylinder. .........................................................................8.9 8.6 Control valve U*S .......................................................................................................................8.10 8.7 Setting the hose rupture valve ....................................................................................................8.10 8.8 Calibrating the hydraulic controls ...............................................................................................8.11 8.9 Hydraulic diagram .......................................................................................................................8.11
ATLET SERVICE MANUAL U - AC Power Plus
8.1
8.2
ATLET SERVICE MANUAL U - AC Power Plus
8
Hydraulic system
The hydraulic system is speed controlled. The pump motor, pump, hydraulic oil tank and hydraulic oil filter are integrated in a module, which can be easily lifted out from the truck if necessary. The hydraulic system consists of: •
an oil tank with integrated return oil filter (replaceable filter insert) and filter for air evacuation from the tank.
•
a pump unit consisting of an electric motor and pump.
•
an electrically operated valve assembly that consists of several different sections (number and design can vary due to different equipment).
An electrical signal is sent from the joystick to the ATCII when the hydraulic functions are manoeuvred. The ATCII then controls the hydraulic pump’s speed and the electrically operated valves.
The hydraulic oil then goes from the valve assembly through the hydraulic pipes and hoses to the cylinders. Of these only the lift cylinders are single acting, the others are all double acting. The lift cylinders are retracted by the weight of the fork carriage. In the double acting cylinders it is the oil pressure that retracts the piston rod.
Figure 8.1
A socket is located on the pressure pipe between the pump and the actuator valve for pressure metering, see pos 8 figure 8.1. Setting the lowering speed is done using an adjuster screw on the valve assembly, see section 8.6 Control valve U*S. A hose rupture valve is located on the outlet on the lift cylinder which closes the oil flow if a hose ruptures and prevents the forks from falling down, see section 8.7 Setting the hose rupture valve for setting.
ATLET SERVICE MANUAL U - AC Power Plus
8.3
8.3
Replacing the suction hose
1
Empty the oil from the tank. See section 8.4
2
Dismantle the hydraulic filter complete.
3
Remove the suction hose from the pump.
4
Remove the suction hose from the tank using an open-ended spanner and a hook spanner.
5
Lift out the suction hose through the hole for the filter.
6
Assemble in the reverse order. (Always fit new O-rings and connect the hose to the pump before tightening the tank, so that the hose routing will be correct.)
7
Fill with hydraulic oil through the filter.
"
) 8.4
Note! The screws for the filter should be fitted with care to avoid damaging the threads in the tank. IMPORTANT! Do not forget the earth connection between the suction line and the chassis.
50
Draining the tank
1
Lower the forks to their lowest position and depressurise the system.
2
Loosen the rubber clamp holding the pressure hose on the battery wall.
3
Loosen the pressure hose from the valve.
4
Fold out the hose and place in a container.
5
Start the pump motor and carefully “pump” out the oil into a container. (Carried out slowly to prevent cavitation in the pump when the tank is empty.)
"
49
Note! Always use new oil when refilling.
Figure 8.4
Warning! Exercise care when loosening the hose and pumping out the oil as this is under great pressure and can cause serious damage/injury. ATLET SERVICE MANUAL U - AC Power Plus
8.5
8.3
Replacing the suction hose
1
Empty the oil from the tank. See section 8.4
2
Dismantle the hydraulic filter complete.
3
Remove the suction hose from the pump.
4
Remove the suction hose from the tank using an open-ended spanner and a hook spanner.
5
Lift out the suction hose through the hole for the filter.
6
Assemble in the reverse order. (Always fit new O-rings and connect the hose to the pump before tightening the tank, so that the hose routing will be correct.)
7
Fill with hydraulic oil through the filter.
"
) 8.4
Note! The screws for the filter should be fitted with care to avoid damaging the threads in the tank. IMPORTANT! Do not forget the earth connection between the suction line and the chassis.
50
Draining the tank
1
Lower the forks to their lowest position and depressurise the system.
2
Loosen the rubber clamp holding the pressure hose on the battery wall.
3
Loosen the pressure hose from the valve.
4
Fold out the hose and place in a container.
5
Start the pump motor and carefully “pump” out the oil into a container. (Carried out slowly to prevent cavitation in the pump when the tank is empty.)
"
49
Note! Always use new oil when refilling.
Figure 8.4
Warning! Exercise care when loosening the hose and pumping out the oil as this is under great pressure and can cause serious damage/injury. ATLET SERVICE MANUAL U - AC Power Plus
8.5
8.5
Cylinders
Mast reach cylinders and tilt cylinders are double acting.
8.5.1
Dismantling the reach cylinder from the truck
1
Reach out the mast to its outermost position and lower the forks to their lowest position.
2
Remove the nut, pos 12, in the rear mounting. The axle, pos 15, can be held using an allen key from below.
3
Remove the axle, pos 15.
4
Retract the cylinder with the lever for the reach function by moving it backwards.
5
Pull out the battery plug.
6
Remove and plug the pressure hose to the mast reach cylinder.
7
Remove the axle in the cylinder’s front mounting.
8
Lift out the cylinder.
Figure 8.5
Assemble the cylinder in the reverse order.
8.5.2
Dismantling the tilt cylinder from the truck Warning! When dismantling the tilt cylinders, one or both, the mast must be secured so that it does not tip backwards. Remember that a tilt cylinder can be faulty, which can cause an accident.
1
Tilt the mast to it foremost position and lower the forks to their lowest position.
2
Loosen the pressure hoses to the cylinder.
3
Dismantle the axles on the front and rear mountings.
4
Lift out the cylinder.
8.6
ATLET SERVICE MANUAL U - AC Power Plus
8.6
Control valve U*S
8.7
Setting the hose rupture valve
8.10
ATLET SERVICE MANUAL U - AC Power Plus
8.5.4
Bleeding the mast shift cylinder
If you suspected air to be in the cylinder (jerky movement), the following operations can be done: 1
Run out the reach carriage.
2
Dismantle the axle, pos 15.
3
Run out the piston a little. (IMPORTANT! Check that the piston rod is not damaged.)
4
Dismantle the swivel head, pos 11 from the piston rod. Dismantle the hexagonal nut and the tab washer, pos 9 and 10.
5
Run the cylinder slowly in and out, to its innermost and outermost positions, several times so that any air is pressed out.
6
Assemble the cylinder and make an operations test.
E 206.2
Figure 8.7
8.8
ATLET SERVICE MANUAL U - AC Power Plus
8.6
Control valve U*S
8.7
Setting the hose rupture valve
8.10
ATLET SERVICE MANUAL U - AC Power Plus
9.2
ATLET SERVICE MANUAL U - AC Power Plus
110703:E 1/1
Service Manual U - AC Power Plus Manual No: 005953 Section:9 Issue: A
9 Lift cylinders ..................................................................................9.3 9.1 Dismantling, assembling the free lift cylinder ..............................................................................9.3 9.2 Dismantling, assembling the final stroke cylinder ........................................................................9.3 9.3 Draining, bleeding the cylinders ...................................................................................................9.4 9.4 Dismantling, assembling the free lift cylinder ..............................................................................9.4 9.5 Dismantling, assembling the final stroke cylinder ........................................................................9.5
ATLET SERVICE MANUAL U - AC Power Plus
9.1
9.2
ATLET SERVICE MANUAL U - AC Power Plus
9
Lift cylinders
9.1
Dismantling, assembling the centre cylinder
1
Lower the forks to the lowest position.
2
Remove the hoses, pos 3 on the lower part of the cylinder.
3
Dismantle the chain bolt, pos 4, with the chain by the cylinder by loosening the nut, pos 12.
4
Undo the bolt, pos 5, in the cylinder’s lower mounting from below.
5
Dismantle the clamp, pos 6, around the cylinder.
6
Lift out the cylinder.
9
10
11
7
1
1
4 6
Assemble in the reverse order.
9.2
8
11 2
12
Dismantling, assembling the outer cylinders
1
Place a 10 cm wooden block under the intermediate mast.
2
Lower the mast so it rests on the wooden block.
3
Dismantle the bolt, pos 8.
4
Lower so that the cylinder retracts completely.
5
Dismantle the oil pipe to the cylinder and plug.
6
Dismantle the bolt, pos 9 and lift out the cylinder.
3
5
SM 182.1
Figure 9.1
Assemble in the reverse order.
ATLET SERVICE MANUAL U - AC Power Plus
9.3
9.3
Draining, bleeding the cylinders
1
Lift the forks approx. 0.5 metres above the floor.
2
Loosen the bleeding screws, pos 25 figure 9.2 and pos 13 figure 9.3 a little to bleed the cylinders. Tighten the screws when oil starts to run out.
3
Lift the forks to the top position. Perform this lift 3 times.
4
Let the forks stay in the top position for a while.
5
Bleed the cylinders again, until all the air has been evacuated from the system.
6
The cylinders must not close more than 5 mm.
9.4
Dismantling, assembling the centre cylinder
1
Remove the safety clamp, pos 6.
2
Lift off the yoke, pos 11.
3
Unscrew the top nut, pos 14.
4
Pull out the piston rod, pos 17.
5
Before assembling, change the seals and sliding element, lubricate them with hydraulic oil.
19 19
20
21 21
1 3
2
22
4 35
24
5 25
5
Assemble in the reverse order.
6 7
33
9
11
31
A
9
10
32 30
17
8
23
27
12
13
14
15
16
18
28 F 207.3
Figure 9.2
9.4
ATLET SERVICE MANUAL U - AC Power Plus
9.5
Dismantling, assembling the outer cylinder
1
Unscrew the top nut, pos 6, use a hook spanner.
2
Pull out the piston rod, pos 5.
3
Before assembling, change the seals and sliding element, lubricate them with hydraulic oil.
3 2 10
Assemble in the reverse order. 11 9
"
Note! Before assembling check that no impact marks or large scratches have been made on the cylinder tube or piston rod as these can cause leakage. Generally the cylinder tube and piston rod should be handled carefully to prevent damage. Also ensure that seals and O-rings are not damaged during assembly.
A
8
5
12
6
1
13
14
12
17
15 16 4
F 206.1
Figure 9.3
ATLET SERVICE MANUAL U - AC Power Plus
9.5
9.6
ATLET SERVICE MANUAL U - AC Power Plus
10.16 Horn ...................................................................................................................................... 10.27 10.17 Warnings ............................................................................................................................... 10.27 10.18 Menu tree ATC ..................................................................................................................... 10.28 10.18.1 Log of faults .............................................................................................................. 10.35 10.18.2 Subinfo ...................................................................................................................... 10.35 10.18.3 General instructions with all types of faults on trucks .............................................. 10.35 10.19 Trouble shooting ................................................................................................................... 10.36 10.19.1 Low temp drive or Low temp hydraulics - Warning on the display ......................... 10.36 10.19.2 The truck and ATC are “dead”: ................................................................................. 10.37 10.19.3 Warning low battery in combination with E02 B+ on the chassis: ........................... 10.38 10.19.4 Electric servo: ............................................................................................................ 10.39 10.19.5 Symptom: The pump motor’s speed gradually drops ............................................... 10.41 10.19.6 Symptom: The pump regulator’s status lamp flashes on and off .............................. 10.42 10.19.7 Symptom: Main connectors do not make once the truck is logged on. .................... 10.44 10.19.8 Symptom: The fuse for the power supply has blown. ............................................... 10.45 10.19.9 Symptom: The drive regulator’s status lamp flashes on and off ............................... 10.46 10.19.10 Symptom: The drive motor only runs at a low speed with a ticking noise. ............ 10.47 10.19.11 Symptom: High pump motor temperature ............................................................. 10.49 10.19.12 Symptom: The drive motor’s speed gradually drops .............................................. 10.50 10.19.13 Symptom: (High drive motor temperature) ............................................................. 10.51 10.19.14 The pump motor only runs at a low speed with a ticking noise. ............................. 10.51 10.19.15 Drive system stopped/ Hydraulics stopped Subinfo: Controller not responding .... 10.54 10.19.16 Drive system stopped/ Hydraulics stopped Subinfo: Overcurrent e8 ..................... 10.55 10.19.17 Drive system stopped/ Hydraulics stopped Subinfo: DC bus too low e64 ............. 10.56 10.19.18 Drive system stopped/Hydraulics stopped subinfo: No charge DC bus e128 ......... 10.56 10.19.19 Drive system abnormal/ Hydraulics abnormal Subinfo: Controller calib error. w256 .................................................................. 10.57 10.19.20 Drive system abnormal/ Hydraulics abnormal Subinfo: Controller rev to default w512 ............................................................... 10.57 10.19.21 Drive system stopped/ Hydraulics stopped Subinfo: DC bus too high. HW e16 ..................................................................... 10.58 10.19.22 Drive system stopped/ Hydraulics stopped Subinfo: ATC contradictory. e2048 ..................................................................... 10.59 10.19.23 Drive system abnormal/ Hydraulics abnormal Subinfo: “Controller temp sensor W2” or subinfo: “sensor w4” ......................... 10.59 10.19.24 Drive system abnormal/ Hydraulics abnormal Subinfo: Speed signal out of range. w 128 ........................................................... 10.60 10.19.25 Drive system abnormal/ Hydraulics abnormal Subinfo: Motor temp sens lost. w32: Motor temp sens shorted. w64 .................. 10.61 10.19.26 Subinfo: CAN too many errors. e256 ...................................................................... 10.62 10.19.27 Subinfo: CAN watchdog time-out. e512 ................................................................. 10.62 10.20 Trouble shooting chart – movement functions ..................................................................... 10.63 10.20.1 Lift function does not work - other functions OK ..................................................... 10.63 10.20.2 The reach-in function does not work – other functions OK ...................................... 10.65 10.20.3 The reach-out function does not work – other functions OK .................................... 10.67 10.20.4 The drive function does not work, one or two directions .......................................... 10.69 10.20.5 Lowering of the forks does not work ........................................................................ 10.71 10.21 Trouble shooting chart battery stop ...................................................................................... 10.72 10.22 Menu tree, leaves .................................................................................................................. 10.73 10.23 Wiring diagram ................................................................................................................... 10.116 10.2
ATLET SERVICE MANUAL U - AC Power Plus
10
Electrical system, general
The electrical system consists of: •
a 48 Volt battery
•
an ATC
•
a drive regulator
•
a pump regulator
•
a number of sensors both microswitch models (solenoids) and analogue-digital models.
•
sensors for steering
•
connectors for connection of the power circuits
•
electric motors for driving the transmission and hydraulic pump
•
electric brakes
•
electric steering
•
electric fans
•
electrically controlled hydraulic valves
Trucks equipped for use in cold storage facilities have covered cabs with electric heating and lighting as extra equipment. Some trucks are equipped with radio equipment. Other electrical installations may be encountered due to specific customer requirements. These are not taken up in this Service Manual.
ATLET SERVICE MANUAL U - AC Power Plus
10.3
10.1
Safety procedures
•
Electric powered vehicles can be dangerous. All testing, trouble shooting and adjusting must be carried out by authorised personnel. The drive wheel should run free of the floor and be able to run freely during work.
•
Take off watches and rings before starting repair and trouble shooting work.
•
The electrical system has a multi-stage safety system to provide the highest possible level of safety. Abnormal conditions are detected and depending on the type of fault different measures are implemented. The least critical condition only generates a warning via the display. Faults that may result in dangerous situations result in a stop and trouble shooting assistance via the error log.
•
The battery must always be disconnected with all replacement and repair work on the electrical system.
•
It is essential that all cables (especially the battery cables) are connected correctly as the electronics used in the truck are sensitive to incorrectly polarised supply voltage.
•
All dust and magnetic particles should be regularly cleaned from solenoid switches and magnets to guarantee operations.
•
Extreme importance must be placed on precautionary measures to avoid accidents during all work on the vehicle. A general rule is to always implement preventive measures that are adapted to the type of vehicle to be worked on. The general rules below must always be observed:
•
Smoking or naked flames are strictly forbidden as there is a risk of explosion in the vicinity of batteries and while working on gas equipped vehicles. The battery should always be protected during grinding work. The fire regulations for the building shall also be observed.
•
The truck shall always be lifted so that the drive wheel is free of the ground to prevent the vehicle from running away. The vehicle must not rest solely on the jack, but must be secured by some form of blocking.
•
The battery plug must always be removed on electric reach trucks to prevent the risk of injuries caused by crushing. The mast, carriage and power pack can be actuated due to an electrical fault or mistake while working. The battery plug may only be connected while trouble shooting and when the greatest of care is exercised, (with the truck raised).
•
During work on and around the mast and power pack, these must be locked using the mast lock, wooden blocks or other appropriate material. No other persons may be in the vicinity of the truck when this is test run in combination with repair work as there is a risk of incidents and accidents occurring due to the truck making an unexpected manoeuvre. Warning! To stand on the carriage between the mast and battery partition with the current connected to the truck can represent Mortal danger!
•
The system should not be pressurised, for example, the pump motor shutoff and the forks down, when dismantling parts of the hydraulic system.
10.2
Connectors in cold storage rooms
Grease Kryotox ATLET article number 110781 should be applied to all electrical connectors in the machine housing and mast/mast base on cold store designed models. The hand applicator, part number 110782, should be used in order to do this. The grease should be applied to contactor surfaces when the connectors are drawn apart. The contactors are then reconnected and the grease is pressed from behind into 10.4
ATLET SERVICE MANUAL U - AC Power Plus
the contactor housing so that this is filled.
)
IMPORTANT! Connectors filled with Kryotox should not be treated with 3M. In general the electrical system is treated as before.
10.3
Dismantling, assembling the drive and pump regulators
•
Dismantling the panels, see section 4.
•
Loosen the cables connected to the regulators.
•
Check that the cables are labelled, if not label the cables before removing.
•
Loosen the bolts holding the regulators. Most bolts are accessible without the need of dismantling the bracket.
•
Assemble in the reverse order.
)
IMPORTANT! When fitting a new regulator, check that the air tunnel where the regulator is mounted is free of dust, etc.
10.4
Routine test of the insulation resistance
You must first disconnect the connections (plugs) before the truck is insulation tested in order to protect the regulators and other electrical components on the truck. This is because damage can occur, which will shorten the life of component parts. In the event of large insulation errors it is appropriate to use a universal instrument until the error has been found and then make a final insulation test. This applies to all electronic units on the truck. Warning! The instrument has a dangerous voltage across the measurement poles, Do not touch the poles during testing. Routines for insulation testing of all truck models. 1
Take out the insulation measurement instrument.
2
Set the test voltage to 100 volt.
3
Pull out the battery plug. Disconnect connections/terminals to electrical components and electronic systems before the test is performed as these can be damaged by the test voltage.
4
Connect the instrument’s earth lead to the truck chassis at a point with good electrical contact. The other lead is connected to the electrical panel plug’s positive pole.
5
Press the start button and wait until the display has stabilised, now release the button and read off the value on the display. An approved value on 48 volt trucks shall be at least 48,000 ohm, (48 kohm).
6
Let the earth lead remain attached to the chassis and connect the other lead to the electrical panel plug’s negative pole. Now repeat point 5. ATLET SERVICE MANUAL U - AC Power Plus
10.5
10.5
Atlet’s truck computer ATC
The ATC system consists of a keyboard and display in three parts and an ATC unit.
sm 199.1
Figure 10.1
Display: The top row is used for information. The lower row is the status row.
1 9 - AU - 9 4 75
0 7 : 48 1 0H
sm 200.1
Figure 10.2
The lower row (75%), indicates here the remaining battery capacity. (10h), indicates here the total running time.
1 9 - AU - 9 4 75
0 7 : 48 1 0H
sm 202.1
Figure 10.3
Here a hare indicates normal speed while a tortoise indicates low speed. The down arrow is used for speed on/off.
1 9 - AU - 9 4 75
0 7 : 48 1 0H
sm203.1
Figure 10.4
10.6
ATLET SERVICE MANUAL U - AC Power Plus
Error messages are shown in the form of a code (E15).
1 9 - AU - 9 4 7 5 E1 5
0 7 : 48 1 0H
sm 201.1
Figure 10.5
10.5.1
General
The service functions are activated via the “S” (service) key on the keyboard. These functions are divided into levels, Driver, Local Service, Atlet Service and Customer Service. The Driver level allows the language to be changed as well as tuning of the truck’s travel and hydraulic characteristics. On the Local level it’s possible to change the ID and password for the driver and local service, set the speed and lift controls, check inputs and outputs, read statistics and make a hardcopy. A password must be entered to select any of the Local Service functions. On the ATLET level it’s possible to change all IDs and passwords, set parameters for the height preselection, set options, read the error log, make hardcopies and download settings from another ATC or PC. A password must be entered to select any of the ATLET Service functions. The Customer Service level allows reading and printing of statistical information, communication with PSION palm-sized computers, unlocking of a collision-locked truck and resetting of customer logs and counters. The menu that appears once the correct password has been entered will be abbreviated. This is because only the menu title and one menu option (0: Exit) are shown. You can browse through the menus using the number and arrow keys, while the “Enter” key selects the menu. When you enter a form, i.e. where it is possible to change parameter values, you should use the arrow keys when you do NOT wish to change the values. If you wish to make changes enter the new numerical values and confirm using “Enter”. If you make a mistake you must continue to the closest end point and start again. In some functions it is possible to go back using the arrow key.
ATLET SERVICE MANUAL U - AC Power Plus
10.7
10.5.2
Service functions
The service functions are primarily used to facilitate the ATLET Service. In addition, the service functions make it possible to read off all the measurements made using the Measurement/Statistics functions. Functions included are: •
Changing the ID and password for Driver, Local and ATLET service levels.
•
Checking that microswitches and cables on inputs function.
•
Checking that digital outputs and cables function.
•
Calibrate and check the operation of the accelerator pedal.
•
Calibrate and check the operation of the brake pedal.
•
Calibrate and check the operation of the hydraulic levers.
•
Reports of Measurement/Statistic functions.
•
Read and reset running times.
•
Read and reset the error log.
•
Hardcopies.
•
Download settings from another ATC or PC.
10.5.3
Change passwords.
It is possible to change the service password as well as the driver’s ID and password.
10.5.4
Calibration and control of the hydraulic levers.
Hydraulic levers are calibrated by measuring the maximum stroke and neutral position for this function.
10.8
ATLET SERVICE MANUAL U - AC Power Plus
10.5.5
Running time functions
The running times of the following units are read off: •
Total usage.
•
Pump motor on 5 levels.
•
Forwards.
•
Backwards.
The running time of each unit presented in hours. The maximum number of hours is 99999. When printing the running hours are also calculated and shown as a percentage of the total usage. The running hours can either be reset for all units or individually.
10.5.6
Printing of statistics
A function is available under CUSTOMER Service to print all statistic functions either individually or all at once. Any serial printer or a PC can be used for this purpose.
10.5.7
Collision sensor
This function requires a special sensor mounted on the chassis. The program has 5 adjustable limits and when one of these is exceeded one or more of the following functions are activated: 1
A warning message is shown on the display.
2
The truck’s normal horn is activated and produces an intermittent signal.
3
The truck’s warning lights come on.
4
The truck logs off.
5
A special password is required to stop the above.
When one of the 5 levels is exceeded a warning text is shown on the display at the same time as the impact force of the collision is stored with the time, date and driver ID in the customer log.
ATLET SERVICE MANUAL U - AC Power Plus
10.9
Switches should be connected as illustrated. (input)
Normal Common 4.5 Volt SM 204.1 Figure 10.7 . Input
The appearance of the input.
100k
2k2
100nF
sm 194.1
Figure 10.8
The appearance of the servo input. +5 Volt
4k7
100k
100nF
sm 195.1
Figure 10.9
ATLET SERVICE MANUAL U - AC Power Plus
10.11
10.5.11 Description of the digital outputs. There are 35 outputs on the ATC distributed across a number of output connectors. The outputs are specified for 0.1A, 1A and 3A. All outputs feature overload protection. 12 of the outputs use an optional voltage, for example, 12 volt or B+ The choice of voltage is made by connecting the selected voltage to XC5:23.
Lowering outputs. a)
b)
c) 16 Volt
Sence
Sence R
Sence R
Watchdog
sm 196.1
Figure 10.10
Supply outputs.
Watchdog
sm 197.1
Figure 10.11
10.12
ATLET SERVICE MANUAL U - AC Power Plus
24 Volt
R
10.5.12 Digital outputs: B+ fed Connector
Function
Type
Remarks
XC3:10 XC3:11
Reverse steering wheel indicator Forward steering wheel indicator
1.0A A High 1.0A A High
+ / Supply + / Supply
XC3:21 XC3:22 XC1:22 XC1:23 XC1:24 XC4:23 XC1:21 XC8:22
Buzzer Main connector Brakes Flashing lights Horn Key relay Reserved Constant current valve level selector
1.0 A Low 1.0 A Low 3.0A A Low 1.0 A Low 3.0A A Low 0.1A A Low 1.0 A Low 1.0 A Low
- / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply
XC8:23 XC6:23 XC6:24 XC2:22 XC3:01 XC3:08
Reserved Lamp rail wheel 0 degrees Lamp rail wheel 90 degrees Position light Reserved Reserved
1.0 A Low 1.0 A Low 1.0 A Low 0.1 A Lamp 0.1 A High 0.1 A High
- / Supply - / Supply - / Supply - / Supply + / Supply + / Supply
Type
Remarks
0.1 A Lamp 0.1 A Lamp 0.1 A Lamp 0.1 A Lamp 0.1 A Lamp 0.1 A Lamp 0.1 A Lamp
- / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply
10.5.13 Digital outputs 12 Volts supply Connector XC2:11 XC2:21 XC3:05 XC3:06 XC3:02 XC3:03 XC3:04
Function Not connected Not connected Automatic drive wheel rotation anticlockwise UFS Automatic drive wheel rotation clockwise UFS Truck-on lamp Straight steering lamp Brake lamp
ATLET SERVICE MANUAL U - AC Power Plus
10.13
10.5.14 Digital outputs B+ supply Connector XC5:01 XC5:02 XC5:03 XC5:04 XC5:05 XC5:06 XC5:07 XC5:08 XC5:09 XC5:10 XC5:11 XC5:12
10.6
Function B+ lift valve plate B+ PWM lower valve plate B+ Reach IN B+ Reach OUT B+ tilt IN B+ tilt OUT B+ side shift pedal side B+ side shift seat side B+ fork spread OUT B+ fork spread IN 5V PWM supply steering wheel indicator B+ PWP regulator fan
Type 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low 1.0 A Low
Remarks - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply - / Supply
Valve parameters
A description of the valve section, lift/lowering is given below, however, the same applies to reach, tilt, side shift, rotate/side shift. Nevertheless, it may be problematic to determine which movements correspond to POSITIVE. Lift, reach-in, tilt up, rotate clockwise, forks together and side shift towards the driver are all POSITIVE movements.
POS MAX DUTY POS MIN DUTY NEG MAX DUTY NEG MIN DUTY JOYST.DEADZONE
Pump output for maximum positive movement (max. lift). Pump output for minimum positive movement (min. lift). Pump output for maximum negative movement (max. lower). Pump output for minimum negative movement (min. lower). The number of steps from the neutral position that the joystick must be moved before any actuation is made on the pump. This applies to both the positive and negative movements. POSITIVE ACC Damping of increasing pump output for positive movement. POSITIVE RET Damping of decreasing pump output for positive movement. NEGATIVE ACC Damping of increasing pump output for negative movement. NEGATIVE RET Damping of decreasing pump output for negative movement. FETCH B./SCALEF Must not be changed!
10.14
ATLET SERVICE MANUAL U - AC Power Plus
10.6.1
Checking and adjusting values.
POS MAX DUTY and NEG MAX DUTY define the speed of the movement at max. joystick actuation, these are not normally changed, but if you want calmer/slower movement, for example, while tilting these parameters can be reduced. POS MIN DUTY for lifting should be set so that when the joystick starts the pump, for a lift with empty forks and for forks under free lift, the forks do NOT move. NEG MIN DUTY for lowering should be set so that it’s possible to gradually run the pump or lowering movement with a minimum of joystick actuation (lower values give lower speeds). FETCH B./SCALEF. for reach is used for battery retrieval and for lift is used as a limiter for the overall pump output with simultaneous movement. The value is set to “1” with the battery on the rollers to shutdown the function.
10.7
Battery capacity measurement.
The battery capacity is shown as a percentage of a fully charged battery to the left of the lower row on the display. Measurements are fully controlled by software, and no further electronics are required. The battery capacity is measured by measuring the battery voltage when the truck has been at rest for 3 minutes. If the period between measurements becomes too long, the ATC uses the running time counter to calculate the capacity. When the battery capacity becomes too low a warning message is given on the display’s top row and the battery capacity value starts to flash. The truck speed is limited to “creep speed”. Lift stop with a weak battery is linked to the battery capacity measurement. Both the warning level and the stop level are set in the service function.
Battery capacity%
Voltage 48 V sys.
Acid density g/cm3
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
45.84 45.95 46.06 46.17 46.28 46.39 46.50 46.61 46.72 46.83 46.94 47.05 47.16 47.28 47.39
1.070 1.075 1.079 1.084 1.088 1.093 1.098 1.102 1.107 1.111 1.116 1.121 1.125 1.130 1.134
ATLET SERVICE MANUAL U - AC Power Plus
10.15
10.16
Battery capacity%
Voltage 48 V sys.
Acid density g/cm3
30 32 34 36 38 40 42 44
47.50 47.61 47.72 47.83 47.94 48.05 48.16 48.27
1.139 1.144 1.148 1.153 1.157 1.162 1.167 1.171
46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100
48.38 48.49 48.60 48.71 48.82 48.93 48.04 49.15 49.26 49.37 49.48 49.59 49.70 49.81 49.92 50.04 50.15 50.26 50.37 50.48 50.59 50.70 50.81 50.92 51.03 51.14 51.25 51.36
1.176 1.180 1.185 1.190 1.194 1.199 1.203 1.208 1.213 1.217 1 222 1.226 1.231 1.236 1.240 1.245 1.249 1.254 1.259 1.263 1.268 1.272 1.277 1.282 1.286 1.291 1.295 1.300
ATLET SERVICE MANUAL U - AC Power Plus
10.7.1
Battery parameters version 3.00 -
Select 48V batt.
Nominal battery voltage, state 1 for 48 Volt, 0 for 24 Volt. 48 Volt is Default. Actual battery voltage to ATC. You can make corrections for voltage losses in cables and connectors up to the ATC by changing these values. To make the Measured B+ correction, measure the battery voltage at the poles using a voltmeter that can (mV) show 4 digits at 50 Volts, then state the voltage in mV. (If the voltmeter shows 48.12 Volt, press 48120 Ent). Battery size (Ah) Stated in Ah. This is normally stated on the battery. Default is 550. Pump size (kW) State in whole kW. Default is 14. Usage, stated from 50 to 200 per cent, and used to correct for light/hard driving. Utilisation (%) The standard is 100. Higher values are used with harder driving, lower values for lighter driving. Calculation constant to receive a warning of whether the chassis has an Chassis const. 1 unpermitted HIGH voltage depending on too low resistance between the chassis and the battery’s positive pole. See table. Default is 917. Chassis const. 2 Low batt. level Lift stop level
10.8
Calculation constant to receive a warning of whether the chassis has an unpermitted LOW voltage depending on too low resistance between the chassis and the battery’s negative pole. See table. Default is 110. Determines at what percentage of the battery capacity that the ATC shall warn that it is time to charge the battery. Default is 25%. Determines at what percentage of the battery capacity that the ATC should shutdown the lift function and limit the driving speed to crawling speed. Default is 20%.
Checking the chassis connection ATC
(This is performed in combination with replacing the ATC). 1
This should be checked using a calibrated DMM in order to determine whether the ATC makes good contact with the rest of the chassis. Set the digital multimeter to resistance measurement, measurement range 200 Ohm. Touch the measurement probes together and read off the display, it should be 0.0 to approx. 0.6 Ohm.
2
Connect one of the measurement probes to one of the bright screw heads on the ATC box and the other probe to the screw for the chassis connection, (located on the battery wall under the ATC connection green/yellow cable). The value read off should not be more than max. 0.5 Ohm higher than the read off value under point 1.
3
If the value is higher make a check on some of the other screws on the ATC box. If this does not help the screw for the chassis connection must be checked. First check by measuring this across another clean metal surface, if the value is also too high the thread for the chassis connection should be cleaned using a plug tap and a new check should be performed.
)
IMPORTANT! Chassis faults should always be rectified during the servicing.
10.9
Potential measurement on the truck chassis.
The potential measurement is performed with a voltage divider connected between B+ and B-, with the ATLET SERVICE MANUAL U - AC Power Plus
10.17
centre outlet connected to the chassis. The voltage divider has sufficiently large resistance to comply with EU’s insulation requirements at the same time as potential changes can be measured via an analogue input on the ATC. If voltage is discovered on the chassis an error code is displayed. The error code is stored together with the time and date in the error log.
10.10
Error codes
Check the error log and write down or print out the contents of the log before starting any trouble shooting. Error codes and sub-information that reoccurs within a twenty-four hour time frame (00:00 - 23:59) is not logged, which is why the log must be emptied in order for the fault to be logged again. Please note: That there is more information available for codes marked by an asterisk by pressing the I button when reading the error log. The extra information is always included in the printout. Codes within brackets are not used in version 3.30 or later.
10.10.1 List of error codes Error code (E01) E02 E03 (E04) E05 E06 E07 (E08) E09 E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 (E21) (E22) (E23) 10.18
Error text High temperature Chassis + voltage Chassis - voltage Cable fault Servo tacho fault Servo motor fault Servo regulator fault Fk7 fault Several chassis faults Joystick fault NVR small fault NVR total reset NVR forced reset Battery par. reset Serv. par. reset Valve par. reset Travel. par. reset Options reset err 19 err 20 Motor carbon brush worn P1 carbon brush worn P2 carbon brush worn
ATLET SERVICE MANUAL U - AC Power Plus
Error code
Error text
(E24) (E25) E26 E27 E28 E29 E30 (E31)
Servo carbon brush worn Brake lining worn NV2 small fault NV2 total reset NV2 forced reset NVR -> MITTOR MITTOR -> NVR Motor overheated
(E32) (E33) (E34) E35 E36 E37 E38 E39 E40 (E41) (E42) (E43) (E44) (E45) (E46) (E47) E48 (E49) E50 E51 E52 E53 E54 E55 E56 E57 E58 (E59) E60 E61 E62 E63
P1 overheated P2 overheated Servo overheated Hyd oil overheated Temp1 overheated. Temp2 overheated. ATC overheated. err 39 NV3 forced reset Chassis to In. Output to In. Unknown chassis fault Chassis to Out. Chassis to BChassis to B+ No. of inputs Brake sensor low err 49 err 50 F6 Fuse blown F8 Fuse blown F7 Fuse blown err 54 err 55 err 56 err 57 err 58 Test command error Wheel angle sensor Rotation sensor err 62 err 63
ATLET SERVICE MANUAL U - AC Power Plus
10.19
Error code
10.20
Error text
E64* E65* E66* E67 E68 E69 E70 E71
High short-circuit Low short-circuit Lmp short-circuit High out intermittent Low out intermittent Lamp out intermittent High output unknown Low output unknown
E72 E73 E74 E75 E76 E77 E78 E79 E80* E81* E82* E83* E84* E85* E86* E87 E88 E89* E90* E91* E92* E93 E94 E95* E96* E97* E98* E99* E100* E 101*
Lamp output unknown Deletion error NV1 Program. error NV1 Deletion error NV2 Program. error NV2 Deletion error NV3 Program. error NV3 err 79 TRAP error bus TRAP error instr TRAP error word TRAP error prot TRAP error oper TRAP error stun TRAP error stof err 87 err 88 Stack error Division with zero Calculation error INTERNAL error err 93 err 94 CAN hardware CAN software Drive sys stopped Hydraulic stopped CAN fatal error Drive sys abnormal Hydraulic abnormal
ATLET SERVICE MANUAL U - AC Power Plus
10.11
Temperature measurement
Temperature measurements are made using NTC resistance (Negative Temperature Coefficient). The temperature can be shown from 0 to approx. 150 °C. ATC has 6 channels to measure the temperature. When the temperature is too high the driver receives an error message on the display. This takes place in two stages. The temperature limiters can be set from the service function. The first stage involves an error message and the second stage involves a new error message and e.g. the pump/drive motor being shutdown. The following statistics are saved for the temperature: The number of times the temperature has been reached in intervals: Only the oil temperature is measured with NTC resistance in Power Plus. In the drive and pump motor systems the temperature is measured in the regulators and motors using PTC resistance. The temperature is reported to the ATC via the CAN network.
Oil
Motors and regulators
Temp. above 75 °C
above 120 °C
Temp. 71 - 75 °C Temp. 66 - 70 °C Temp. 61 - 65 °C Temp. 56 - 60 °C
111 - 120 °C 101 -110 °C 91 -100 °C 81 -90 °C
10.11.1 One of the hydraulic functions channels 3, 4 and 5 See the trouble shooting chart for reach-out, trouble shooting corresponds with the function channels 3, 4 and 5 with the symbol and connector definitions as set out below.
Function
Symbol
Tilt out Tilt in Side shift display side Side shift seat side Fork spread in Fork spread out
to TO ti TI SSR >< SO < > SC
ATLET SERVICE MANUAL U - AC Power Plus
Connector P82,1 P82,2 P81,1 P81,2 P53,1 P53,2 P50,1 P50,2 P54,1 P54,2 P51,1 P51,2
10.21
10.12
Battery replacement
Use the reach lever when replacing or extracting the battery. 1
Move in the reach carriage until it stops.
2
Continue to activate the lever at the same time as the arrow up key on the keyboard is pressed. The reach carriage will then slide in a little further.
3
Loosen the battery stop by pressing down the pedal with your right foot on U*S. Keep holding down and move out the reach carriage. The battery will now follow out.
4
Replace the battery and then run in the reach carriage until it stops, Continue to activate the lever at the same time as the arrow up key on the keyboard is pressed. The reach carriage will then slide in a little further. The battery is locked automatically when it reaches its innermost position.
5
Now run out the reach carriage and check that the battery lock has locked correctly.
10.22
ATLET SERVICE MANUAL U - AC Power Plus
SM 179.1
SM 179.1
Figure 10.12
10.13
Setting of the megnet switch for the mast reach stop.
The magnet is adjusted so that the reach movement towards the machine housing stops at A=1-15 mm. The reach speed is set via the valve parameter “set valves”.
A
30
29
32 31 33 35
34
SM 180.1
Figure 10.13
ATLET SERVICE MANUAL U - AC Power Plus
10.23
10.14
Adjustment, calibration and repair instructions
The ATC language should be set to English in order to follow the instructions below. If necessary also refer to the section menu tree.
10.14.1 Performance settings Machine parameters: Each machine model can have its own basic settings. For example, a UNS can have a different top speed compared with a UHS. The parameters are preset at the factory and can only be changed using special PC software. Under normal conditions the factory settings should never be changed after delivery. Further parameter adjustments described below represent percentages of and therefore limit the basic settings. The basic settings are written into the software for ATC II.
Setting of driver categories: Up to four sets of parameters representing performance categories may be defined. The system should be used to define, for example, the two categories “experienced drivers” and “learners”. All parameters are preset at the factory and are only intended to be modified by qualified personnel. Consequently, the setting options are protected under the “ATLET service” 3: ATLET service 4: Settings 1: Performance 1
AC Driver 1 (Preset to normal “experienced drivers” – represents performance according to the data sheet.
2
AC Driver 2 (Preset to a little lower performance than “AC Driver 1”)
3
AC Driver 3 (Preset to “learner performance”)
4
AC Driver 4 (Preset throughout to max. performance. Intended to show the truck’s maximum capacity at demonstrations and must not be set for a driver to perform daily operations.)
Description of parameters in each set (possible setting range in percentage of max.):
Travel speed Crawl speed Acceleration travel Current limit Drive Reduction brake, travel
10.24
Top speed Speed limitation activated by [arrow down] key or by the ATC logic (Tortoise on the display). Time based ramp Max. permitted current limit Braking torque when the accelerator is released.
ATLET SERVICE MANUAL U - AC Power Plus
20 - 100% 10 - 90% 20 - 100% 20 - 100% 0 - 100%
Travel speed Reversing brake, travel Brake pedal Max. speed, reversing Max. pump speed Max. lowering speed Acceleration pump Soft hydraulics Steering sensitivity Steering progressive
Top speed Braking torque when the driving direction is reversed. Braking torque when the brake pedal is used. Top speed in the direction of the forks as a percentage of the “Drive speed” above.
20 - 100% 50 - 100%
Top speed of the pump. Top speed for fork lowering. Current limit. Limits the torque and acceleration. Gentler hydraulic control
50 - 100% 70 - 100% 20 - 100% 0 = off 1 = on
50 - 100% 20 - 100%
Not introduced Not introduced
Individual driver settings Each driver ID code can have its own performance profile, but this must be linked to one of the four driver categories. When a new driver is defined a new question is asked – “Driver category”? - at the end of the sequence. On delivery factory code 1/2222 is linked to “AC Driver 1” category.
)
IMPORTANT! When delivered category 4 is set for the demonstration of the truck’s maximum capacity and should be readjusted if it’s to be used for practical operations.
Factory set values in the different performance categories. Performance category Travel speed Crawl speed Current limit Driving Acceleration travel Reduction brake, travel Reversing brake, travel
1
2
3
4
100 40 100 80 90 75
80 40 90 70 75 70
50 40 80 60 70 70
100 50 100 100 100 100
Brake pedal, travel Max. speed, reversing Max. pump speed Max. lowering speed Acceleration pump Soft hydraulics Extra Steering 1. Extra Steering 2.
100 100 100 100 100 0 100 100
100 80 100 100 100 0 90 90
90 80 90 100 90 1 80 80
100 100 100 100 100 0 100 100
The parameters that the driver can tune make up a percentage of the corresponding category parameters in the category he/she has been placed in. For example, the top speed is set by: Top speed = Machine parameter (see 2.1) × Driver category% (see 2.2) × Driver% Example: Top speed = 12 km/h × 90% × 100% = 10.8 km/h
ATLET SERVICE MANUAL U - AC Power Plus
10.25
)
IMPORTANT! If the parameter Max. speed reverse is set lower than 100% it will also be added to the above calculation example when reversing.
Driver parameters: Each driver can set his/her own performance profile; under the condition that individual driver IDs are used. The performance profile is activated each time the driver starts the truck. Follow the instructions to store your own performance profile. 1
Press the [S] key with the battery plug connected, but in the logged off mode.
2
Select 6 “Driver parameters” by pressing the [6] key, or scroll using the arrow keys. Press [ENT].
3
Enter your unique start code.
4
A parameter menu is displayed: 0. Exit 1. Max. travel speed 20 - 100% 2. Acceleration travel 20 - 100% 3. Reduction braking (‘motor brake’) 0 - 100% 4. Reversing brake 50 - 100%
Default 100% Default 100% Default 70% Default 70%
5
Move to the parameter you wish to change. Use the number keys to define a new value. Save the value by pressing [ENT
6
Press “0. Exit” when finished, followed by [ENT] to leave the menu.
7
Leave the service menu by pressing “0. Exit” and [ENT].
8
Log on to the truck and test drive.
10.15
Fuses Standard fuses
10.26
F1 F4 F5 F2 heavy F3 heavy F4
10A 5A 5A 250A 250A 20A
F6
10A
F7
5A
ATC internal fuses Drive motor Pump motor Servo motor Pump regulator (measurement point B+3) Valve plate Steering wheel indicator Manoeuvre cold storage cab Electric servo and end position switch (measurement point B+4) Drive regulator Extra equipment not supplied by Atlet
ATLET SERVICE MANUAL U - AC Power Plus
Standard fuses F8 F9 F10 F12 F14
5A 10A 5A 5A 5A
Fan door ATC B+ ref (see trouble shooting, warning low battery) Charging circuit regulator Emergency stop circuits Fuses extra accessories
F11 heavy F13
F15 F17 F21 F22
10.16
80A A fuse box with 8 fuses, see wiring diagram 074530 5A 5A 63A 5A
Main supply cold storage cab Interior cold storage cab
Radio Headlamp Motor circuit, motorised battery rollers Manoeuvre, motorised battery rollers
Horn
When connecting the horn the terminals on the terminal block should be turned towards you. Connected according to the standard wiring diagram. Setting the sound: A number of dipswitches labelled 1-5 can be found at the rear of the horn. The switches are set so that 1-3 are closed and 4-5 are open. The tones obtained will then be 970 Hz for the horn and 2850 Hz for the buzzer. There is also a potentiometer screw that can be turned clockwise to the stop to give the maximum sound level.
10.17
Warnings
The ATC display shows a warning message to the side of the described error conditions. Typical warning conditions are when the temperature of a regulator or motor approaches a critical level. This results in reduced power to the overheated unit. However, the truck remains operational. System temperatures under -20°C result in a power reduction and a warning condition. The warning message on the display disappears once conditions return to normal. Function
Warning temperature
Stop temperature
Drive motor Lift motor Drive regulator Lift regulator Hydraulic oil temperature
145 145 85 85 60
165 165 125 125 65
ATLET SERVICE MANUAL U - AC Power Plus
10.27
10.18
Menu tree ATC
Service menu 1: Set language Select language 1.0: Exit and return to "Service menu" 1.1 :English 1.2: Svenska 1.3: Deutsch 1.4: Francais 1.5: Custom lang.1 1.6: Custom lang.2 1.7: Text test OK 2: Local Service ( Password required )(2) Local Service 2.0: Exit and return to "Service menu" 2.1: Set drivercode (2.1) 2.2: Run tests Select test: 2.2.0: Exit and return to "Local service" 2.2.1: Drive test Drive menu: 2.2.1.0: Exit and return to "Select test" 2.2.1.1: Drive inputs(2.2.1.1) 2.2.1.2: Set acceler. (2.2.1.2) 2.2.1.3: Drive outputs(2.2.1.3) 2.2.1.4: Set brake(2.2.1.4) 2.2.1.5: Regulator inp(2.2.1.5) 2.2.1.6: Brake test(2.2.1.6) 2.2.1.7: Calib. wheel(2.2.1.7) 2.2.1.8: Analog wheel(2.2.1.8) 2.2.2: Hydraul. test Hydraul menu: 2.2.2.0: Exit and return to "Select test" 2.2.2.1: Hydr. inputs (2.2.2.1) 2.2.2.2: Read joyst. (2.2.2.2) 2.2.2.3: Pump tests (2.2.2.3) 2.2.2.4: Regulator inp (2.2.2.4) 2.2.2.5: Std. valves(2.2.2.5) 2.2.2.6: Opt. valves (2.2.2.6) 2.2.2.7: Hydr. lamps (2.2.2.7) 2.2.2.8: Calib. joyst.(2.2.2.8)
10.28
ATLET SERVICE MANUAL U - AC Power Plus
2.2.3: Options test Options menu: 2.2.3.0: Exit and return to "Select test" 2.2.3.1: Optional inp. (2.2.3.1) 2.2.3.2: Optional outp (2.2.3.2) 2.2.3.3: Height encod.(2.2.3.3) 2.2.3.4: Temp. inputs (2.2.3.4) 2.2.3.5: Ext. temp. inp(2.2.3.5) 2.2.3.6: AC Regul. temp(2.2.3.6) 2.2.4: Misc. test Misc. menu 2.2.4.0: Exit and return to "Select test" 2.2.4.1: Battery test (2.2.4.1) 2.2.4.2: Chassis test (2.2.4.2) 2.2.4.3: Horn test (2.2.4.3) 2.2.4.4: Custom test Cust.Test menu 2.2.4.4.0: Exit to "Misc test" 2.2.4.4.1: Custom inputs (2.2.4.4.1 2.2.4.4.2: Custom output (2.2.4.4.2 2.2.4.4.3: Custom calibr (2.2.4.4.3 2.2.4.4.4: Custom spare (2.2.4.4.4 2.2.4.5: Spare 2.3: Log & counter Log & counters 2.3.0: Exit and return to "Local service" 2.3.1: Read tmp. log (2.3.2) 2.3.2: Read err. log (2.3.3) 2.3.3: Read total c (2.3.3) 2.3.4: Read work. c (2.3.4)
#4
2.4: Set time/date Clock menu 2.4.0: Exit and return to "Local service" 2.4.1: Read time (2.4.1) 2.4.2: Read date (2.4.2) 2.4.3: Set time (2.4.3) 2.4.4: Set date (2.4.4) 2.4.5: Set date form (2.4.5) 2.4.6: Set day of w (2.4.6)
ATLET SERVICE MANUAL U - AC Power Plus
10.29
3: Atlet service ( Password required ) ATLET service 3.0: Exit and return to "Service menu" 3.1: Set passwords Password menu 3.1.0: Exit and return to "ATLET service" 3.1.1: Set ATLET code (3.1.1) 3.1.2: Set def. drive (3.1.2) 3.1.3: Del one passw. (3.1.3) 3.1.4: Set local code (3.1.4) 3.1.5: Set def. local (3.1.5) 3.1.6: Set cust. code (3.1.6) 3.1.7: Set def. cust. (3.1.7) 3.1.8: Set passw. par. (3.1.8) 3.2: ATLET counters Counters menu 3.2.0: Exit and return to "ATLET service" 3.2.1: Read custom (4.4.1) 3.2.2: Read working (2.3.4) 3.2.3: Read total (2.3.3) 3.2.4: Reset custom (4.5.1) 3.2.5: Reaset working (3.2.5) 3.3: Set options (3.3) 3.4: Settings menu Select setting: 3.4.0 Exit and return to "ATLET service" 3.4.1: Performance AC parameters 3.4.1.0: Exit and return to "Settings menu" 3.4.1.1: AC driver 1(3.4.1.X) 3.4.1.2: AC driver 2(3.4.1.X) 3.4.1.3: AC driver 3(3.4.1.X) 3.4.1.4: AC driver 4(3.4.1.X) 3.4.2: Set valves 3.4.2.0: Exit and return to "Settings menu" 3.4.2.1: Lift param. (3.4.2.X) 3.4.2.2: Ch 1 param (3.4.2.X) 3.4.2.3: Ch 2 param (3.4.2.X) 3.4.2.4: Ch 3 param (3.4.2.X) 3.4.2.5: Ch 4 param (3.4.2.X)
#6
3.4.3: Set battery 3.4.4: Set levelsyst.
(3.4.3) (3.4.4)
3.5: Spare 3.6: Spare 10.30
ATLET SERVICE MANUAL U - AC Power Plus
3.7: Run tests Select test: 3.7.0: Exit and return to "ATLET service" 3.7.1 Drive test Drive menu: 3.7.1.0: Exit and return to "Select test" 3.7.1.1: Drive inputs(2.2.1.1) 3.7.1.2: Set acceler. (2.2.1.2) 3.7.1.3: Drive outputs(2.2.1.3) 3.7.1.4: Set brake(2.2.1.4) 3.7.1.5: Regulator inp(2.2.1.5) 3.7.1.6: Brake test(2.2.1.6) 3.7.1.7: Calib. wheel(2.2.1.7) 3.7.1.8: Analog wheel(2.2.1.8) 3.7.2: Hydraul.test Hydraul menu: 3.7.2.0: Exit and return to "Select test" 3.7.2.1: Hydr. inputs (2.2.2.1) 3.7.2.2: Read joyst. (2.2.2.2) 3.7.2.3: Pump tests (2.2.2.3) 3.7.2.4: Regulator inp (2.2.2.4) 3.7.2.5: Std. valves(2.2.2.5) 3.7.2.6: Opt. valves (2.2.2.6) 3.7.2.7: Hydr. lamps (2.2.2.7) 3.7.2.8: Calib. joyst.(2.2.2.8) 3.7.3: Options test Options menu: 3.7.3.0: Exit and return to "Select test" 3.7.3.1: Optional inp. (2.2.3.1) 3.7.3.2: Optional outp (2.2.3.2) 3.7.3.3: Height encod.(2.2.3.3) 3.7.3.4: Temp. inputs (2.2.3.4) 3.7.3.5: Ext. temp. inp(2.2.3.5) 3.7.3.6: AC Regul. temp(2.2.3.6)
ATLET SERVICE MANUAL U - AC Power Plus
10.31
3.7.4: Misc. test Misc. Menu 3.7.4.0: Exit and return to "Select test" 3.7.4.1: Battery test (2.2.4.1) 3.7.4.2: Chassis test (2.2.4.2) 3.7.4.3: Horn test (2.2.4.3) 3.7.4.4: Custom test 3.7.4.4.0: Exit and return to "Misc test" 3.7.4.4.1: Custom inputs (2.2.4.4.1 3.7.4.4.2: Custom output (2.2.4.4.2 3.7.4.4.3: Custom calibr (2.2.4.4.3 3.7.4.4.4: Custom spare (2.2.4.4.4 3.7.4.5: Spare #3
3.7.5: Acquisition Acquision menu 3.7.5.0: Exit and return to "Select test" 3.7.5.1: Read data(3.7.5.1) 3.7.5.2: Print data(3.7.5.2) 3.7.5.3: Setup acq. 1(3.7.5.X) 3.7.5.4: Setup acq. 2(3.7.5.X) 3.7.5.5: Setup acq. 3(3.7.5.X) 3.7.5.6: Setup acq. 4(3.7.5.X) 3.7.5.7: Setup acq. 5(3.7.5.X) 3.7.5.8: Clear all acq. 3.7.5.9: Reset all acq. 3.7.6: Spare 3.7.7: Test any output (3.7.7) 3.7.8: Show inputs (3.7.8) 3.7.9: System setup
#5
3.8: ATLET logbook Log book menu: 3.8.0: Exit and return to "ATLET service" 3.8.1: Read tmp log (2.3.1) 3.8.2: Read err. log (2.3.2) 3.8.3: Read service (3.8.3) 3.8.4: Sign service (3.8.4) 3.8.5: Reset service 3.8.6: Reset tmp.log 3.8.7: Reset err.log 3.8.8: NVR upload (3.8.8) 3.9: Set all def.
10.32
ATLET SERVICE MANUAL U - AC Power Plus
4: Custom serv. Custom service 4.0: Exit and return to "Service menu" 4.1: Unlock (4.1) 4.2: Communication (4.2) 4.3: Printout Print Custom 4.3.0: Exit and return to "Custom service" 4.3.1: Print counters (4.3.X) 4.3.2: Print cus.log (4.3.X) 4.3.3: Print tmp.log (4.3.X) 4.3.4: Print srv.log (4.3.X) 4.3.5: Print err. log (4.3.X) 4.3.6: Print settings (4.3.X) 4.3.7: Spare 4.3.8: Print all log (4.3.X) 4.4:Readout Read custom 4.4.0: Exit and return to "Custom service" 4.4.1: Cust. counter (4.4.1) 4.4.2: Cust. log 4.5: Reset custom ( password required )(4.5) Reset custom 4.5.0: Exit and return to "Custom service" 4.5.1: Cust. counter 4.5.2: Cust. log #5
4.6: Show inputs
(3.7.8)
5: Startup 6: Driver param.
(6)
ATLET SERVICE MANUAL U - AC Power Plus
10.33
Comments: #1
Removed in issue C
#2
Removed in issue B
#3
See document M330 for more information.
#4
Format code 1: dd-mon-yy Format code 2: dd-mm-yyyy Format code 3: mm-dd-yyyy Format code 4: yyyy-mm-dd
#5 Line 1 shows "Ana.inp XCnn.pp" or "Dig.inp XCnn.pp" where nn is the connector number and pp is pin number. #6
Either select function by pressing key ‘1' to ‘5' or touch the joystick for the function.
#7 Asks for password and then goes thru options list ( 3.3), calibration of speed pedal ( 2.2.1.2) and hydraulic levers ( 2.2.2.8).
10.34
ATLET SERVICE MANUAL U - AC Power Plus
10.18.1 Log of faults ATC has a log containing the last found 30 faults. This can be servo faults, lift sensor faults, speed controller faults, etc. Each fault is traced with the time and date. All faults found by ATC are given a code. Significant error codes are shown on the display’s lower row until they are “acknowledged” by reading the fault log. Minor error codes are traced in the fault log without being displayed. When reading the error code is translated to text.
10.18.2 Subinfo Error codes with underlying subinfo menu. Read the fault log in the log and bring up subinfo by “pressing” the I on the keyboard!
10.18.3 General instructions with all types of faults on trucks in combination with a power failure. •
ATC seems as if it does not work as it should, check the internal fuses F1, F4 and F5 in the ATC.
•
Check the nine measurement points in the form of insulation support under the instrument panel.
•
B+ should be B+ 48V when the battery plug is fitted.
•
B- should be B- 0V when the battery plug is fitted.
•
B+2 should be B+ 48V when the emergency stop is “pulled up”.
•
AGND (analogue earth) should be 0V.
•
B 12V should be 12V.
•
B 5V should be 5V.
•
B+3 should be B+ 48V when the truck is logged on.
•
B+4 should be B+ 48V when the truck is logged on.
•
B+5 should be B+ 48V when the truck is logged on and the servo is active.
•
If B+ or B- deviate, check the battery plug, electrical panel plug and associated cable connections.
•
If B+2 deviates, check the fuse F14 and the emergency stops SE1 and SE2. Also check that the connectors K11 and K12 through the visual inspection of the contact strips and that the coils are not short circuited and that the freewheel diodes across the coils are intact. Check the connectors’ cable connections too.
•
If AGND deviates, check the connections between AGND measurement point and ATC XC1.10. If AGND is broken it gives a calibration error. If AGND is not put out by ATC, change the ATC.
•
If B12V deviates, check the connections between B12V and ATC XC3.17. If B12V is broken the indicating lamps will not light. Ensure that nothing loads 12V by pulling out all ATC connectors except XC9, also disconnect the CAN bus, now check whether the ATC puts 12V out on pin XC3.17, if not change the ATC.
•
If B+3 deviates, check the fuse F6 and connections from the key relay K3.30 to K3.87, if the relay ATLET SERVICE MANUAL U - AC Power Plus
10.35
does not make check the coil resistance (should be approx. 300 ohm), the freewheel diode across both relay coils and cable connections to the ATC XC1.17 and XC1.27. If the relay circuit is OK, check that B+ 48V puts out on ATC XC1.17 and that the output XC4.23 draws to 0V when logging on, if not, replace the ATC. •
If B+4 deviates, make a check as set out above but on F7 and K6.30, K6.87
•
If B+5 deviates, go to trouble shooting electric servo.
•
If B+5V deviates, check that the cable connections between B5V and ATC XC1.11 are intact. Ensure that nothing loads 5V by pulling out all ATC connectors except XC9, also disconnect the CAN bus, now measure whether there is 5V on the measurement points or XC1.11, if not change the ATC.
10.19
Trouble shooting
10.19.1 Low temp drive or Low temp hydraulics - Warning on the display
Drive the truck at a reduced speed and reduced load until the regulator has warmed up to approx. 20 degrees for full operating capacity. Or
Ø Drive the truck in a heated building until the regulator has reached the temperature for full operating capacity.
10.36
ATLET SERVICE MANUAL U - AC Power Plus
10.19.2 The truck and ATC are “dead”: Is there 48V between B+ and Binsulators?
Ö No
Check the battery, battery plug, electrical panel plug and associated connections.
Yes
Ø Is the electrical emergency stop in the emergency stop position?
Ö
Pull up the button for the emergency stop.
Yes
No
Ø Is B+ 48V on the insulator B+2?
Ö No
Check the contactor circuits K11 and K12. Check that the fuse F14 has not failed and that the emergency stop switches failed SE1 and SE2 are made to 48V. If the fuse has failed check the contactor K10, K11 and K12 so that none of the coils are short circuited and that the freewheel diodes are intact.
Yes
Ø Are the ATC internal fuses F1 and F5 intact?
Ö
Change the fuses.
No
Yes
Ø Ö
Is the fuse F9 intact?
Change the fuse.
No Yes
Ø Is there B+ 48V to the ATC connectors XC9.1 and XC9.2?
Ö No
Check the cable routing between B+2 and ATC and between B- and ATC.
Ø Change the ATC!
ATLET SERVICE MANUAL U - AC Power Plus
10.37
10.19.3 Warning low battery in combination with E02 B+ on the chassis: The battery supply shows 00% depending on a fault occurring before or after logging on. It is not possible to lift after lowering.
Is the fuse F10 with fuse holder intact?
Ö
Change the fuse/fuse holder!
No Yes
Ø Is there a connection between B+2 and XC9.5 in ATC?
Ö
Change the cable!
No
Yes
Ø Does the truck seem OK otherwise?
Ö No
Check the battery voltage and the battery connections!
Yes
Ø Change the ATC!
10.38
ATLET SERVICE MANUAL U - AC Power Plus
10.19.4 Electric steering: E05 is a servo tacho fault, E06 is a servo motor fault, E07 is a servo regulator fault.
Do the faults occur together resulting in the drive no longer working?
Ö No
Check that the servo’s safety relay K4 is made, if not, the probable fault lies with one of the limit switches for the servo. Check the red LEDs 2 and 3 in the servo box, both the bistabile switches shall be open when the drive unit is in the end positions, otherwise closed. Change the servo box! Change the motor!
Yes
Ø Is the green lamp on the servo box on?
Ö No
Check the fuse F7 and measurement point B+4, see the general instructions for a power failure.
Ö
Check the tachometer and its cables. The tachometer should give increasing voltage with speed/wheel turning. If the cables are okay, replace the tachometer, or replace the servo box.
Yes
Ø E05 or tacho fault logged? Tip: Red LED “ERROR 4” lights on the control box if the fault occurs during operations and the truck has not been logged off. If the tacho fault arises when the truck is logged off the fault is not logged, error code E97 is shown.
Yes
No
Ø E05 or servo motor fault logged? Red LED Error 5 lit on the control box.
Ö
See “Important” comments below.
No Yes
Ø
ATLET SERVICE MANUAL U - AC Power Plus
10.39
Check that the motor fuse F4 is intact. Check that there is a low resistance between the motor’s poles, the carbon brushes should be made. Check the motor cables. Make a visual inspection of the servo connector strips to ensure they are OK. Check that the coil resistance is approx. 70 ohm and that the cables are OK. Check that the freewheel diode across the contactor coil is intact. Continue
Ø
Change the servo box! Change the servo motor!
)
IMPORTANT! Error codes E05 tacho fault, E06 servo motor fault and E07 servo regulator fault are generally overwritten by error code E97.
)
IMPORTANT! If both the LEDs ERROR 4 and ERROR 5 are on, the servo box should be replaced (E07).
10.40
ATLET SERVICE MANUAL U - AC Power Plus
10.19.5 Symptom: The pump motor’s speed gradually drops (High temperature on the pump regulator) Was the warning text “High tmp hydrau C” visible on the display when the symptom occurred?
Ö
Go to high pump motor temperature.
No
Yes
Ø Check that the regulator fan works as it should by first removing the battery plug and then restarting the truck again.
Ø Does the fan start within about 20 seconds?
Ö Yes
Check that nothing obstructs the air flow through the regulator’s heatsinks. If the heatsinks are covered in dust or other objects, clean under these!
No
Ø Connect a voltmeter and repeat the procedure to check the regulator fan! .................................................................. Is the voltage at least B+ 48V for a few seconds after the fan has started?
Ö Yes
Change the fan!
No
Ø Ö
Is there B+ 48V on the fan?
No
Check the cables between the fan connector X26.1 and the ATC contact XC5.19 carefully. If the cables are OK and the truck has no other faults, change the ATC!
Yes
Ø Check the cables between the fan connector X26.2 and the ATC contact XC5.12 carefully. If the cables are OK and the truck has no other faults, change the ATC!
ATLET SERVICE MANUAL U - AC Power Plus
10.41
10.19.6 Symptom: The pump regulator’s status lamp flashes on and off 1. The truck shall be logged on.
Ö
Does the status lamp flash?
Yes
Look for an error code and go to the related trouble shooting chart.
No (the status lamp is off)
Ø
2. Is there a supply voltage B+ 48V to the regulator’s connector E2 K1.1
Ö
Go to point 5 below.
No
Yes
Ø Ö
3. Battery voltage low?
Charge and check the battery!
Yes No
Ø 4. Change the pump regulator!
Ø 5. B+ 48V at measurement point B+4?
Ö
Go to point 8 below.
No Yes
Ø 6. Check the connection between B+4 and the regulator’s contact E2 K1.1
Ø 7. Change the drive regulator!
8. Is the fuse F7 intact?
Ö
Change the fuse.
No Yes
Ø
10.42
ATLET SERVICE MANUAL U - AC Power Plus
9. Is the relay K6, B+48 on connection K6.87 activated?
Ö No
Change the relay!
Yes
Ø 10. Check the cable connection between the measurement points B+4 and K6.87!
If none of the key relays K3 and K6 are activated (the drive regulator’s status lamp is also off). Check the coil resistance, which should be about 300 ohm, that the freewheel diode across the coils are intact and that there is a supply via the ATC.
ATLET SERVICE MANUAL U - AC Power Plus
10.43
10.19.7 Symptom: Main connectors do not close once the truck is logged on. ATC is voltage fed. Have any related error codes been logged?
Ö Yes
See the trouble shooting chart for respective error codes!
No
Ø B+ 48V to the main contactor’s coil?
Ö No
Check that the emergency stop circuits are intact!
Yes
Ø B- to the main contactor’s negative side?
Ö No
Check the connection between the main connector’s negative side and the ATC!
Ø If these are OK, replace the ATC! Perhaps the ATC does not put out B- to the connector’s coil.
Yes
Ø Are the connector’s coil and its freewheel diode intact?
Ö
Change the connector/diode!
No
Yes
Ø Change the regulator!
10.44
ATLET SERVICE MANUAL U - AC Power Plus
10.19.8 Symptom: The fuse for the power supply has failed. The probable cause for a blown fuse is a short circuit in the regulator’s power stage or that the average current exceeds the fuse’s rated current.
Change the fuse (with correct fuse value) and restart!
Ø Does the fuse fail just after the main contactor has made?
Ö Yes
Change the drive regulator/pump regulator! Tip: If the drive or pump motor fuse has blown when starting the error code E97 or E98 is given with the subinfo: “No charge DC-bus” E128.
No
Ø Start the truck again!
Ø Does the fuse fail again after the truck has been running for some time?
Ö Yes
Check that the mechanical torque in the gearbox is not too great due to worn parts or, e.g. that the pump jams.
Ø If the truck has been run with a heavy load and at a high speed and with many stops and starts or in any other way exceeded its limitations, try to reduce the speed, load, acceleration and retardation (braking).
Increased friction, increased load, high speed and rapid starting/stopping increase the average current from the regulator. The truck may have been driven over its maximum performance! Warning! Always make sure that the regulators are correctly discharged by removing the battery plug and waiting for 2 minutes before fuses are changed, risk for arcing.
ATLET SERVICE MANUAL U - AC Power Plus
10.45
10.19.9 Symptom: The drive regulator’s status lamp flashes on and off 1. The truck shall be logged on.
Ö
Does the status lamp flash?
Yes
Look for an error code and go to the related trouble shooting chart.
No (the status lamp is off)
Ø
2. Is there a supply voltage B+ 48V to the regulator’s connector E1 K1.1
Ö
Go to point 5 below.
No
Yes
Ø Ö
3. Battery voltage low?
Charge and check the battery!
Yes No
Ø 4. Change the drive regulator!
Ö
5. Does the servo work?
Yes
Check the connections between B+5 and the regulator’s connector E1 K1.1
No
Ø The steering probably has no supply voltage or the safety system has tripped. Go to the trouble shooting chart for the electric servo.
Ø
A flashing status lamp means the drive regulator has indicated a fault. When the status lamp is off this means that the drive regulator is not receiving any supply voltage or that the internal program has not been run.
Change the drive regulator!
10.46
ATLET SERVICE MANUAL U - AC Power Plus
10.19.10 Symptom: The drive motor only runs at a low speed with a ticking noise. Or the motor attempts to start, but cannot run or runs unevenly with a low torque. 1. Are the motor cables correctly connected and make good contact between the drive motor and the drive regulator?
Ö No
Tighten the connections or replace the motor cables.
Yes
Ø 2. Switch the regulators. Note that in most cases the drive and pump regulators can be switched with each other for test purposes. First check that the article numbers correspond with each other.
Ù
IMPORTANT! If you cannot switch the regulators go to point 4.
Ö No
If the fault moves to the pump motor system, change the drive regulator that is now fitted in the pump regulator’s place!
Ö
Go to point 8 below.
Ø 3. Is there still a fault with the drive motor system. Yes
Ø 4. Is the voltage on the motor cable between M1.1 and M1.2 approx. 12V DC?
No
Yes
Ø 5. Is the voltage at E1 K1.5 and E1 K1.6 approx. 4V DC with E1 K1.4 as a reference when the motor rotates, alternatively 0V or 8V DC when the motor is at a standstill.
Ö Yes
After checking the drive regulator’s connections, change the drive regulator.
No
Ø 6. Is the voltage at M1.3 and M1.4 approx. 4 V DC with M1.2 as a reference when the motor rotates? Alternatively 0V or 8V DC when the motor is at a standstill.
Ö No
After checking the motor’s connector connections, change the drive motor.
ATLET SERVICE MANUAL U - AC Power Plus
10.47
Yes
Ø 7. Look for the break/short circuit in the cables between the drive regulator and the drive motor M1.4 - E1 K1.5 and M1.3 - E1 K1.6 and between M1.3 and M1.4. Both connectors are pulled out of their connections on the motor and drive regulator.
8. Is the voltage between the drive regulator and the contact points E1 K1.3 and E1 K1.4 approx. 12V?
Ö Yes
Check that there is not a break or short circuit in the cables between the motor contact and the drive regulator contact, both connectors are pulled out of their connections. Measure between E1 K1.3 E1 K1.4 and between M1.1 - E1K1.3 and M1.2 - E1 K1.4.
No
Ø 9. Change the drive regulator!
10.48
ATLET SERVICE MANUAL U - AC Power Plus
10.19.11 Symptom: High pump motor temperature 1. Was the warning text “High tmp hydrau M” visible on the display when the symptom occurred?
Ö No
Start using the truck again and ask the truck driver to report any new warning messages!
Ö
Go to point 4 below.
Yes
Ø 2. Does the machine housing fan work?
No Yes
Ø 3. * Check that nothing obstructs the air flow to the motor. * If the motor is dirty, clean it! * Let the truck rest until the temperature has dropped! * If the truck works above its specified capacity the acceleration and speed must be lowered or the current limit lowered.
4. Connect a voltmeter to the fan. Is the voltage B+ 48V?
Ö No
Check that the fuse F8 has not failed and that the cables are intact! Also check the thermostat if the truck is in the cold store design!
Yes
Ø 5. Change the fan
)
IMPORTANT! If the truck is allowed to continue working despite the temperature warnings it can result in an automatic stop of the drive motor system, the error codes will be E98 with “Hydraulics stopped” subinfo will be “motor temp too high e2” or “controller’s temp too high e4” registered in the log. If the temperature is allowed to drop to the normal level again, the truck will rum at full capacity again.
ATLET SERVICE MANUAL U - AC Power Plus
10.49
10.19.12 Symptom: The drive motor’s speed gradually drops (High drive regulator temperature) Was the warning text “High tmp drive C” visible on the display when the symptom occurred?
Ö
Go to, symptom: high drive motor temp.
No
Yes
Ø Check that the regulator fan works as it should by first removing the battery plug and then restarting the truck again.
Ø Does the fan start within about 20 seconds?
Ö Yes
Check that nothing obstructs the air flow through the regulator’s heatsinks. If the heatsinks are covered in dust or other objects, clean under these!
No
Ø Connect a voltmeter and repeat the procedure to check the regulator fan! .................................................................. Is the voltage at least B+ 48V for a few seconds after the fan has started?
Ö Yes
Change the fan!
No
Ø Ö
Is there B+ 48V on the fan?
No
Check the cables between the fan contact X26.1 and the ATC contact XC5.19 carefully. If the cables are OK and the truck has no other faults, change the ATC!
Yes
Ø Check the cables between the fan contact X26.2 and the ATC contact XC5.12 carefully. If the cables are OK and the truck has no other faults, change the ATC!
10.50
ATLET SERVICE MANUAL U - AC Power Plus
10.19.13 Symptom: (High drive motor temperature) 1. Was the warning text “High tmp drive M” visible on the display when the symptom occurred?
Ö No
Start using the truck again and ask the truck driver to report any new warning messages!
Ö
Go to point 4 below.
Yes
Ø 2. Does the machine housing fan work?
No Yes
Ø 3. * Check that nothing obstructs the air flow to the motor. * If the motor is dirty, clean it! * Let the truck rest until the temperature has dropped! * If the truck works above its specified capacity the acceleration and speed must be lowered or the current limit lowered.
4. Connect a voltmeter to the fan. Is the voltage B+ 48V?
Ö No
Check that the fuse F8 has not failed and that the cables are intact! Also check the thermostat if the truck is in the cold store design!
Yes
Ø Change the fan
)
IMPORTANT! If the truck is allowed to continue working despite the temperature warnings it can result in an automatic stop of the drive motor system, the error codes will be E97 with “Drive stopped” subinfo will be “motor temp too high e2” or “controller’s temp too high e4” registered in the log. If the temperature is allowed to drop to the normal level again, the truck will rum at full capacity again.
ATLET SERVICE MANUAL U - AC Power Plus
10.51
10.19.14 The pump motor only runs at a low speed with a ticking noise. 1. Are the motor cables correctly connected and make good contact between the pump motor and the pump regulator?
Ö No
Tighten the connections or replace the motor cables.
Yes
Ø 2. Switch the regulators. Note that in most cases the drive and pump regulators can be switched with each other for test purposes. First check that the article numbers correspond with each other.
Ù
IMPORTANT! If you can not switch the regulators go to point 4.
Ø 3. Is there still a fault with the pump motor system.
Ö No
Change the pump regulator that is now fitted in the drive regulator’s place!
Yes
Ø 4. Is the voltage on the motor cable between M2.1 and M2.2 approx. 12V DC?
Ö
Go to point 8 below.
No
Yes
Ø 5. Is the voltage at E2 K1.5 and E2 K1.6 approx. 4V DC with E2 K1.4 as a reference when the motor rotates; alternatively 0V or 8V DC when the motor is at a standstill?
Ö Yes
After checking the pump regulator’s connections, change the pump regulator.
No
Ø 6. Is the voltage at M2.3 and M2.4 approx. 4 V DC with M2.2 as a reference when the motor rotates; alternatively 0V or 8V DC when the motor is at a standstill?
Ö No
After checking the motor’s connector connections, change the pump motor.
Yes
Ø 10.52
ATLET SERVICE MANUAL U - AC Power Plus
7. Look for the break/short circuit in the cables between the pump regulator and the pump motor M2.4 – E2 K1.5 and M2.3 – E2 K1.6 and between M2.3 and M2.4. Both connectors are pulled out of their connections on the motor and drive regulator.
8. Is the voltage between the pump regulator and the contact points E2 K1.3 and E2 K1.4 approx. 12V?
Ö Yes
Check that there is not a break or short circuit in the cables between the motor contact and the pump regulator contact, both connectors are pulled out of their connections. Measure between E2 K1.3 – E2 K1.4 and between M2.1 – E2K1.3 and M2.2 – E2 K1.4.
No
Ø 9. Change the pump regulator!
ATLET SERVICE MANUAL U - AC Power Plus
10.53
10.19.15 Drive system stopped/ Hydraulics stopped Subinfo: Controller not responding
Drive motor system: Check that it is not the electric servo system that is giving the alarm and is caused by a break to the regulator see section 10.19.4 Electric steering:
Ø Check the CAN bus cables and terminations between the ATC and motor regulator extremely carefully. The most probable cause is a break on one of the four CAN bus wires.
Ø Try changing the motor regulator or switching the regulators.
Ø Change the ATC!
10.54
ATLET SERVICE MANUAL U - AC Power Plus
10.19.16 Drive system stopped/ Hydraulics stopped Subinfo: Overcurrent e8 Overcurrent arises when the regulator’s load impedance drops under a minimum value. This is often caused by a short circuit in the regulator’s output stage, in the heavy cable connection between the motor and regulator or in the motor.
Switch off the voltage, wait a few seconds and switch on the voltage again.
Ø Ö
Subinfo: Overcurrent e8
Finished!
No Yes
Ø Check the motor cables for a short circuit between U-V, U-W and V-W, also check that the phases are not short circuited or have inferior insulation to the chassis!
In order to measure a short circuit in the motor cables they must be unscrewed from the insulation supports on both the regulator and motor sides!
Ø Change the regulator!
Ø Subinfo: Overcurrent e8
Ö
Finished!
No Yes
Ø Change the motor!
ATLET SERVICE MANUAL U - AC Power Plus
10.55
10.19.17 Drive system stopped/ Hydraulics stopped Subinfo: DC bus too low e64
10.19.18 Drive system stopped/Hydraulics stopped subinfo: No charge DC bus e128 Error code E 97: If the motor fuse for the drive motor has blown when starting you receive the message: “Drive stopped subinfo: No charge DC bus e128”
Error code E 98: If the motor fuse for the hydraulic motor has failed when starting you receive the message: “Hydraulics stopped subinfo: No charge DC bus e128” The fault appears when the regulator’s software detects that the voltage between the + and B- terminals is too low for the regulator to be reliable.
Ö
Is the battery voltage low?
Charge the battery!
Yes No
Ø Does the fault appear when the regulator is delivering high current to the motor?
Ö Yes
Check the supply voltage between the regulator’s + and B- terminal while running. If the voltage is under 70% of the nominal battery voltage, find the voltage drop in the circuits that feed the drive regulator. (Minimum supply voltage is 22V).
No
Ø
Ø
Check the charging circuit. F12 R300 and that the components are intact!
Check the connections to the regulator’s B+, + and B- terminals. Tighten the nuts to 15 Nm!
Ø
Ø
Change the regulator!
10.56
Check the truck’s battery!
ATLET SERVICE MANUAL U - AC Power Plus
10.19.19 Drive system abnormal/ Hydraulics abnormal Subinfo: Controller calib error. w256 Cut the voltage to the truck by pulling out the battery plug, wait a few seconds and then switch on the voltage again.
Ø Warning code w 256 reappears after restarting the regulator?
Ö Yes
Change the pump or drive regulator depending on the which warning code has been logged!
No
Ø Finished!
10.19.20 Drive system abnormal/ Hydraulics abnormal Subinfo: Controller rev to default w512 Change the regulator if the fault arises repeatedly during start up!
ATLET SERVICE MANUAL U - AC Power Plus
10.57
10.19.21 Drive system stopped/ Hydraulics stopped Subinfo: DC bus too high. HW e16 The error occurs when the regulator detects that the battery voltage is too high for reliable regulator operation. This condition normally arises when too much energy has been regenerated (recovered) to the battery or the resistance between the regulator and battery is too high. The battery voltage between the + and Bterminals on the regulator must not exceed 60V DC.
Check the heavy cables between the motor and the regulator and between the regulator and the battery!
Ø Check the line contactor, (connections and connector strips)
The regulator’s measurement of the supply voltage can be defective!
Ø Ö
Is the above OK?
Yes
The requested brake torque can be too high!
No
Ø
Ø
Rectify the cables and connector!
Reduce the amplitude for the brake torque via ATC. See the sections on the pedal brake, reversing brake or reduction brake.
Ø Change the regulator!
Ø Change the battery!
10.58
ATLET SERVICE MANUAL U - AC Power Plus
10.19.22 Drive system stopped/ Hydraulics stopped Subinfo: ATC contradictory. e2048 Cut the voltage to the truck by pulling out the battery plug, wait a few seconds and switch on the voltage again.
Ø Error code 2048 reoccurs after a new start?
Ö
Finished!
No
Yes
Ø Check that the ATC works as it should!
Ø Change the regulator!
10.19.23 Drive system abnormal/ Hydraulics abnormal Subinfo: “Controller temp sensor W2” or subinfo: “sensor w4” Cut the voltage to the truck by pulling out the battery plug, wait a few seconds and switch on the voltage again.
The regulator’s temperature sensor can be defective!
Ø Warning code W2 drive regulator or W4 pump regulator logged after the truck starts?
Ö
Finished!
No
Yes
Ø Change the pump or drive regulator depending on the which warning code has been logged!
ATLET SERVICE MANUAL U - AC Power Plus
10.59
10.19.24 Drive system abnormal/ Hydraulics abnormal Subinfo: Speed signal out of range. w 128 The ATC has sent a speed command to the regulator, which exceeds the user’s maximum speed parameter. The regulator limits the true speed to .
Switch off the voltage to the ATC and regulator by pulling out the battery plug! Start the truck again!
Ø Does the warning message reoccur after a restart?
Ö No
Finished!
Yes
Ø Change the pump or drive regulator depending on the which warning code has been logged!
Ø Change the ATC!
10.60
ATLET SERVICE MANUAL U - AC Power Plus
10.19.25 Drive system abnormal/ Hydraulics abnormal Subinfo: Motor temp sens lost. w32: Motor temp sens shorted. w64 Check that the sensor is OK and not short circuited. Check the cable connection between the motor temperature sensor and the regulator.
Ø If the sensor is defective, change the motor!
The sensor is measured in the 8 way connector on the motor after the truck side cables have been disconnected. If the sensor is OK you should receive a value of about 500 ohm at room temperature, which is measured across pins 7 and 8 on the connector. If the temperature is higher the resistance will increase! In order to check the cable connections, loosen the 8 way contactor on the motor and the 13 way contactor on the related regulator. Measure across pins 7 and 8 on the 8 way contactor, the resistance should be infinite. Measure that the cables are intact between pin 7 on the motor contactor and regulator contactor, and pin 8 on the motor contactor and pin 4 on the regulator contactor, the resistance should be well under 0.5ohm.
Ø
If there is a cable fault (see the explanation to the right), rectify of change the cable!
The regulator’s temperature measurement can be malfunctioning!
Ø Change the regulator!
ATLET SERVICE MANUAL U - AC Power Plus
10.61
10.19.26 Subinfo: CAN too many errors. e256 Check that the CAN bus is not short circuited or that the connector is broken. Also check the termination resistors at the ends are intact and maintain a value of 120 ohm!
The fault can arise when the CAN interface on the regulator has discovered too many communication errors in a message across the CAN bus.
Ø Is the CAN bus’s supply between E1 K1.1 and E1 K1.13 (applies to the drive regulator) or E2 K1.1 and E2 K1.13 (applies to the pump regulator) less than 8V DC?
Ö Yes
Check the CAN bus’s external supply and change the cables if necessary. The CAN bus is fed via ATC 12V, connectors XC9.12 and XC9.7.
No
Ø Change the regulator!
10.19.27 Subinfo: CAN watchdog time-out. e512 The fault arises when the regulator has not received any control message from the ATC under a period exceeding 70 milliseconds.
Does the same fault occur on more than one regulator across the CAN-bus?
Ö Yes
Check that the CAN bus is intact on all nodes!
No
Ø
Ø Change the regulator!
Check the function of the ATC!
Ø Change the regulator!
10.62
ATLET SERVICE MANUAL U - AC Power Plus
10.20
Trouble shooting chart – movement functions
10.20.1 Lift function does not work - other functions OK
If error code E10 (Joyst. fault), check the lift lever function and recalibrate!
Ö
1. Does the pump rotate?
Go to point 7.
Yes No
Ø 2. Does “L” light on the display for hydraulic inputs on the service menu, when the lift lever is activated?
Ö No
Check the control cable for the lift’s lever and the linear lever. If the linear lever is not working it should be replaced and calibrated!
Yes
Ø 3. Is the lift stop activated? The symbol ^ is visible on the display when logging on and LLi is not showing on the menu for extra inputs.
Ö Yes
If the truck is normally fitted with a lift stop, check the sensor and its cables, the signal is cut with a lift stop.
If the truck is not fitted with a lift stop, check to see whether the function has been accidentally selected in the menu “set options”
No
Ø
Rectify or replace!
4. Is the remaining battery capacity less than 20%?
Ö Yes
Is the truck equipped with lifting cut-out, in the event of a low battery lifting is stopped when the capacity is under 20%. Charge the battery!
No
Ø ATLET SERVICE MANUAL U - AC Power Plus
10.63
5. Check that the lift stop with a low battery has not been accidentally set to a too high value! (the pump can be broken).
Ø 6. Follow the trouble shooting chart for AC regulators!
7. B+ 48V valve plate’s connector P61.1?
Ö
Replace the valve plate cables!
No Yes
Ø 8. Is the voltage between P61.1 and P61.2 < 27V with full lever movement? (only needed to be checked if you can safely say that the lowering function does not work)
Ö
Go to point 10.
Yes
No
Ø 9. Replace the valve plate!
10. Breakage or short circuit in the coil between P61.1 and P61.2?
Ö
Change the coil!
Yes
No
Ø 11. Is the cable connection between the valve plate and ATC OK?
Ö
Change the ATC!
Yes
No
Ø Change the cable!
10.64
ATLET SERVICE MANUAL U - AC Power Plus
10.20.2 The reach-in function does not work – other functions OK
IMPORTANT! When measuring voltage across the valve coil the connector shall be connected to the valve plate. In the event of breakage/ short circuit the connector should not be connected.
If error code E10 (Joyst. fault), check the linear lever function and recalibrate!
Ö
1. Does the pump rotate?
Go to point 5.
Yes No
Ø 2. Does “R” = reach-in, light when the linear lever is activated in the menu hydraulic inputs?
Ö No
Check the control cable for the lift’s linear lever and the linear lever. If the linear lever is not working it should be replaced and calibrated!
Yes
Ø 3. Is the symbol “RS” lit in the menu hydraulic inputs?
Ö No
Check that the level has not been accidentally set to 0!
Yes
Ø 4. “RS” = Reach-in stop, shall only be lit when the reach is in the fully retracted position. Check the reach stop switch and related cables. The signal is cut when the reach stop is activated.
5. B+ 48V valve plate’s connector P72.1?
Ö
Change the valve plate’s cable!
No Yes
Ø
ATLET SERVICE MANUAL U - AC Power Plus
10.65
6. Is the voltage between P72.1 and P72.2 < 27V when the reach-in lever is activated?
Ö
Go to point 8.
Yes
No
Ø 7. Replace the valve plate!
8. Breakage or short circuit in the coil between P72.1 and P72.2?
Ö
Change the coil!
Yes
No
Ø 9. Is the cable connection between the valve plate and ATC OK?
Ö
Change the ATC!
Yes
No
Ø Change the cable!
10.66
ATLET SERVICE MANUAL U - AC Power Plus
10.20.3 The reach-out function does not work – other functions OK
If error code E10 (Joyst. fault), check the linear lever function and recalibrate!
Ö
1. Does the pump rotate?
Go to point 4.
Yes No
Ø 2. Does “E” = reach-out, light when the linear lever is activated in the menu hydraulic inputs?
Ö No
Check the control cable for the reach’s linear lever and the linear lever. If the linear lever is not working it should be replaced and calibrated!
Yes
Ø 3. Check that the level for the reach-out has not been accidentally set to 0!
4. B+ 48V valve plate’s connector P71.1?
Ö
Change the valve plate’s cable!
No Yes
Ø 5. Is the voltage between P71.1 and P71.2 < 27V when the reach-out lever is activated?
Ö
Go to point 7.
Yes
No
Ø 6. Replace the valve plate!
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10.67
7. Breakage or short circuit in the coil between P72.1 and P72.2?
Ö
Change the coil!
Yes
No
Ø 8. Is the cable connection between the valve plate and ATC OK?
Ö
Change the ATC!
Yes
No
Ø 9. Change the cable!
10.68
IMPORTANT! When measuring voltage across the valve coil the connector shall be connected to the lever. In the event of breakage/short circuit measuring on the lever the connector should not be connected.
ATLET SERVICE MANUAL U - AC Power Plus
10.20.4 The drive function does not work, one or two directions
IMPORTANT! If the brakes are applied these will hold the truck despite full power. Check that the regulator works, a weak humming noise should be audible.
1. Is the drive function lost in both directions?
With error code E8, check analogue sensor for accelerator and recalibrate!
Ö No
Check in the menu drive inputs whether either Fd or Bd lights when forward or reverse directions are activated!
Yes
Ø 2. Does the motor’s electric brake release when the left-foot switch is activated and any travel direction is selected?
Ö Yes
Check the accelerator’s analogue sensor so that it goes from approx. 2V – 4.95V. If not check mechanism and possibly replace the sensor!
No
Ø 3. Does the symbol “SA” light in the menu drive inputs when the left-foot switch is activated.
Ö Yes
Go to point 5
No
Ø 4. Check the sensor for the left-foot switch and related cables. The signal is made when the left-foot switch is activated!
5. Check that the brakes are not applied and that the cables are intact!
Ø 6. Breakage/short circuit in the brake coil?
Ö
Change the brakes!
Yes
ATLET SERVICE MANUAL U - AC Power Plus
10.69
No
Ø 7. B+ 48V voltage to the brakes when the left-foot switch and travel direction are selected?
Ö
Go to point 9.
No
Yes
Ø 8. Adjust or replace the brakes!
9. Brake switch OK?
Ö
Change the ATC!
Yes No
Ø Rectify!
10.70
ATLET SERVICE MANUAL U - AC Power Plus
10.20.5 Lowering of the forks does not work or works at a low speed. Other hydraulic functions are OK.
If error code E10 “joyst. fault”, check the sensor and recalibrate!
1. Does dD light = lower when lowering is activated in the menu hydraulic inputs?
Ö No
Check the control cable for the linear lever and the linear lever, if the linear lever is not working it should be replaced and a new calibration done.
Yes
Ø 2. Check that the level for lowering has not been accidentally set to 0!
Ø 3. Is the voltage between P61.1 and P61.3 less than 27V when lowering is activated?
Ö
Go to point 5.
Yes
No
Ø 4. Replace the valve plate! Yes
Ø 5. Breakage/short circuit in the coil between P61.1 and P61.3?
Ö
Change the coil!
Yes
No
Ø 6. Is the cable connection between the valve plate and ATC OK?
Ö
Change the ATC!
Yes
No
Ø 7. Change the cable! ATLET SERVICE MANUAL U - AC Power Plus
10.71
10.21
Trouble shooting chart battery stop Indication
Cause
Worn rubber stop
Action
The speed for mast shift is set too Reduce the reach-in speed. high. Mast reach does not work, mast The magnetic switch for the mast Check the function of the switch. runs against the battery. shift stop is defective. Replace the switch! The mast runs against the The magnetic switch for the mast Adjust according to the battery. reach stop is incorrectly instructions! adjusted.
10.72
ATLET SERVICE MANUAL U - AC Power Plus
10.22
Menu tree, leaves
DL1
Driver log 1, truck statistics without PC program
DL2
Driver log 2, truck statistics with a PC program, MDQS ( Davis Derby )
DL1
------
Symbol for a choise. Yes to the left and No to the right. Number value that can variate.
ATLET SERVICE MANUAL U - AC Power Plus
10.73
2:
Local service
2.1
Set drivercode
Code
: ???????
Local service 1:Set drivercode Note 1
User id: ?
Note 3
Driver category 1
Note 2
Old code: ????
Note 2
New code: ????
Note 2
Verify: ????
Password OK
2.2.1.1
Drive inputs
Drive menu: 1: Drive inputs Note 8
10.74
ATLET SERVICE MANUAL U - AC Power Plus
2.2.1.2
Set acceler.
Drive menu: 2: Set acceler. Release acceler. and hit digitkey Push acceler max and hit digitkey
Calibration fail Press Enter
2.2.1.3
Drive outputs
Drive menu: 3: Drive outputs 0 1 2 3 4 5 6 7 ExTrFoBaS1B1B2B3
0
1
Truck on lamp 0:Exit
2
0 1 2 3 4 5 6 7 Func. not
3
0 1 2 3 4 5 6 7 Func. not avail.
4
Speed limit 1 0:Exit 1:Toggle
5
Brake step 1 0:Exit
6
Brake step 2 0:Exit 1:Toggle
7
Func. not avail. Press Enter
ATLET SERVICE MANUAL U - AC Power Plus
10.75
2.2.1.4
Set brake
Drive menu: 4: Set brake Release brakeped and hit digitkey Push brake max and hit digitkey
Calibration fail Press Enter
2.2.1.5
Regulator ing.
Drive menu: 5:Regulator inp Accel. Volt -.-Drive out --%
2.2.1.6
Brake test
Drive menu: 6: Brake test Brake Volt -.-Brake out --%
10.76
ATLET SERVICE MANUAL U - AC Power Plus
2.2.1.7
Calib. wheel
Drive menu: 7: Calib. wheel Pulses per rev. -Indicate forward Press Enter Arrows for FWD
Indicate side Press Enter Arrows for side
2.2.1.8
Analog wheel
Drive menu: 8: Analog wheel Wheel angle xx 8: Analog wheel
2.2.2.1
Hydr. inputs
Hydraul. menu: 1:Hydr. inputs Note 9
ATLET SERVICE MANUAL U - AC Power Plus
10.77
2.2.2.4
Regulator inp
Hydraul. menu: 4:Regulator inp Lift Volt x.yy Pump Out zz%
2.2.2.5
Std. valves
Hydraul. menu: 5: Std. valves
Only on elektric valve block
0 1 2 3 4 5 6 7 ExLiDoRiRoTiTo
0
10.78
1
Lift 0:Exit
1:Toggle
2
Lower 0:Exit
1:Toggle
3
Reach in 0:Exit 1:Toggle
4
Reach out 0:Exit 1:Toggle
5
Tilt in 0:Exit 1:Toggle
6
Tilt out 0:Exit 1:Toggle
ATLET SERVICE MANUAL U - AC Power Plus
2.2.2.6
Opt. valves
Only on elektric valve block
Hydraul. menu: 6: Opt. valves 0 1 2 3 4 5 6 7 ExSrSlRrRl
0
2.2.2.7
Hydr. lamps
1
Sideshift right 0:Exit
2
Sideshift left 0:Exit
3
Rotate 0:Exit
right 1:Toggle
4
Rotate 0:Exit
left 1:Toggle
Hydraul. menu: 7: Hydr. lamps 0 1 2 3 4 5 6 7 ExTiSiRo
0
1
Tilt lamp 0:Exit
2
Sideshift lamp 0:Exit
3
Rotate lamp 0:Exit 1:Toggle
ATLET SERVICE MANUAL U - AC Power Plus
10.79
2.2.2.8
Calib. joyst.
Hydraul. menu: 8: Calib. joyst. Select joyst. 8: Calib joyst.
0,6,7,8,9
1
Channel Lift Max and min Channel Lift and hit digitkey OK ?
Calibration OK Press Enter
2
Calibration fail Press Enter
Channel 2 Max and min Channel 2 and hit digitkey OK ?
Calibration OK Press Enter
10.80
Calibration fail Press Enter
ATLET SERVICE MANUAL U - AC Power Plus
Select channel with digit or with lever
3
Channel 3 Max and min Channel 3 and hit digitkey OK ?
Calibration OK Press Enter
4
Calibration fail Press Enter
Channel 4 Max and min Channel 4 and hit digitkey OK ?
Calibration OK Press Enter
5
Calibration fail Press Enter
Channel 5 Max and min Channel 5 and hit digitkey OK ?
Calibration OK Press Enter
Calibration fail Press Enter
ATLET SERVICE MANUAL U - AC Power Plus
10.81
2.2.3.1
2.2.3.2
Optional inp.
Optional outp
Options menu: 1:Optional inp.
Note 10
Options menu: 2: Optional outp 0 1 2 3 4 5 6 7 ExSiSoFlSt
0
2.2.3.3
Height encod.
1
Func. not avail.
2
Func. not avail.
3
Flash light 0:Exit. 1:Toggle
4
Stright lamp 0:Exit. 1:Toggle
Options menu: 3: Height encod. Note 11
2.2.3.4
Temp.inputs
Options menu: 1:Temp. inputs Oil temp: Dr: --C,Pu:
10.82
--C --C
ATLET SERVICE MANUAL U - AC Power Plus
2.2.3.5
Ext. temp.inp
Options menu: 1:Ext. Temp.inp ATC temp: --C T1 --C,T2 --C
2.2.3.6
AC Regul temp
Options menu: 6:AC Regul.temp Regulator temp Dr: --C,Pu: --C
2.2.4.1
Battery test
Misc menu: 1: Battery test Batt. Volt --.-
2.2.4.2
Chassis test
Misc menu: 2: Chassis test Limits: -.----.Chass. Volt --.-
2.2.4.3
Horn test
Misc menu: 3: Horn test Horn
ATLET SERVICE MANUAL U - AC Power Plus
10.83
2.2.4.4.1
Custom inputs
Cust. test menu 1:Custom inputs
Prepared for special.
Func. not avail. Press Enter
2.2.4.4.2
Custom output
Cust. test menu 1: Custom output
Prepared for special.
Func. not avail. Press Enter
2.2.4.4.1
Custom calibr
Cust. test menu 1: Custom calibr
Prepared for special.
Func. not avail. Press Enter
2.2.4.4.1
Custom spare
Cust. test menu 1:Custom spare Func. not avail. Press Enter
10.84
ATLET SERVICE MANUAL U - AC Power Plus
Prepared for special.
2.3.1
Read tmp. log
Log & counters 1:Read tmp. log Hydr. oil Temp. Hydr. oil ON
If measuring channel is ON, is shown for 1 second
Hydr. oil Temp. 56- 60C: -.-Hydr. oil Temp. 61- 65C: -.-Hydr. oil Temp. 66- 70C: -.-Hydr. oil Temp. 71- 75C: -.-Hydr. oil Temp. 76C: -.--
Drive motor temp
If measuring channel is ON, is shown for 1 second
Drive motor temp Drive motor temp Drive motor temp Drive motor temp Drive motor temp
ATLET SERVICE MANUAL U - AC Power Plus
10.85
Pump motor temp. Pump motor t ON Pump motor temp. 81- 90C: -.--h Pump motor temp. 91-100C: -.--h Pump motor temp. 101-110C: -.--h Pump motor temp. 111-120C: -.--h Pump motor temp. 120C: -.--h
ATLET Computer 56- 60C: -.--h ATLET Computer 61- 65C: -.--h ATLET Computer 66- 70C: -.--h ATLET Computer 71- 75C: -.--h ATLET Computer 76C: -.--h
10.86
ATLET SERVICE MANUAL U - AC Power Plus
Om If measuring mätkanalen channel is är påisvisas ON, under shown1 for 1 sekund second
Extra 1 Temp Extra 1 Temp ON Extra 1 Temp 56- 60C: -.--h
If measuring channel is ON, is shown for 1 second
Extra 1 Temp 61- 65C: -.--h Extra 1 Temp 66- 70C: -.--h Extra 1 Temp 71- 75C: -.--h Extra 1 Temp 76C: -.--h
Extra 2 Temp Extra 2 Temp ON Extra 2 Temp 81- 90C: -.--h
If measuring channel is ON, is shown for 1 second
Extra 2 Temp 91-100C: -.--h Extra 2 Temp 101-110C: -.--h Extra 2 Temp 111-120C: -.--h Extra 2 Temp 121C: -.--h
ATLET SERVICE MANUAL U - AC Power Plus
10.87
Dr regul. temp. 81- 90C: -.--h DR regul. temp. 91-100C: -.--h Dr regul. temp. 101-110C: -.--h Dr regul. temp. 111-120C: -.--h Dr regul. temp. 121C: -.--h
Pu regul. temp. 81- 90C: -.--h Pu regul. temp. 91-100C: -.--h Pu regul. temp. 101-110C: -.--h Pu regul. temp. 111-120C: -.--h Pu regul. temp. 121C: -.--h
10.88
ATLET SERVICE MANUAL U - AC Power Plus
2.3.2
Read err.log
Log & counters 2:Read err. log Upp to 30 errors are shown. Latest error is shown first. Use arrows to navigate.
30 :991228 10:14 i
01 :991012 08:33
2.3.3
Read total c
Log & counters 3:Read total c Truck Total :
---
Logged on Total :
---
Sum of time when any function has been active
Forward drive Total : --Backward drive Total : --Pump total Total :
---
Pump 1 Total :
---
Pump 2 Total :
---
Pump 3 Total :
---
Pump 4 Total :
---
Pump 5 Total :
---
ATLET SERVICE MANUAL U - AC Power Plus
10.89
2.3.4
Read work. c
Log & counters 4:Read work. c Truck Time :
---
Logged on Tid:
---
Forward drive Time : --Backward drive Time : ---
10.90
Pump total Time :
---
Pump 1 Time :
---
Pump 2 Time :
---
Pump 3 Time :
---
Pump 4 Time :
---
Pump 5 Time :
---
ATLET SERVICE MANUAL U - AC Power Plus
Sum of time when any function has been active
2.4.1
Read time
Clock menu: 1: Read time 20:38:15 1: Read time
2.4.2
Read date
Clock menu: 2: Read date 02-03-
Date format can be changed.
2000
2.4.3
Set time
Clock menu: 3: Set time
Note 5
Time setting XX:XX:XX
2.4.4
Set date
Clock menu: 4: Set date
Note 6
Date setting XX-XX-XXXX ä
2.4.5
Set date form
Clock menu: 5: Set date
Date format Note 7
Date form. set. 03-04-2000 2
2.4.6
Set day of w
Clock menu: 6: Set day of w Wednesday Set day 1-7,H,E
ATLET SERVICE MANUAL U - AC Power Plus
10.91
3:
3.1.1
Code :
ATLET service
???????
Password menu 6:Set ATLET code
Set ATLET code
Old code: ???????
New code: ??????? Verify : ???????
Password OK
3.1.2
Password menu 2:Set def. drive
Set def. drive
Reset all Passw? 0:No 1:Yes (No )
3.1.3
Password menu 3:Del. one passw
Del. one passw
User id: ?
Valid ID ? Id not found
10.92
Reset password ? 0:No 1:Yes (No )
ATLET SERVICE MANUAL U - AC Power Plus
Number of digits depends on setting
3.1.4
Set local code
Password menu 4:Set local code Old code : ???????
New code : ??????? Verify : ???????
Password OK
3.1.5
Set def. local
Password menu 5:Set def. local Reset passwords? 0:No 1:Yes (No )
3.1.6
Set cust. code
Password menu 6:Set cust. code Old code : ???????
New code : ??????? Verify : ???????
Password OK
ATLET SERVICE MANUAL U - AC Power Plus
10.93
3.1.7
Set def. cust.
Password menu 5:Set def. cust. Reset passwords? 0:No 1:Yes (No )
3.1.8
Set passw.par.
Password menu 8:Set passw.par.
Can be set from 1 to 7
Id length: 1 Password length: 4
10.94
ATLET SERVICE MANUAL U - AC Power Plus
Can be set from 0 to 7
3.2.5
Reset working
Counters menu 5:Reset working Truck 0:No 1:Yes (No ) Logged on 0:No 1:Yes (No ) Forward drive 0:No 1:Yes (No ) Backward drive 0:No 1:Yes (No ) Pump total 0:No 1:Yes (No ) Pump 1 0:No 1:Yes (No ) Pump 2 0:No 1:Yes (No ) Pump 3 0:No 1:Yes (No ) Pump 4 0:No 1:Yes (No ) Pump 5 0:No 1:Yes (No )
ATLET SERVICE MANUAL U - AC Power Plus
10.95
3.3
Set options
ATLET service 3:Set options Switch levelsys. 0:No 1:Yes (No ) Pulse levelsys. 0:No 1:Yes (No ) Lift limiting 0:No 1:Yes (No ) Yes / No
Lift lim restart 0:No 1:Yes (No )
Custom system 0:No 1:Yes (No ) Yes / No Func. not awail. Press Enter
Hydr. oil Temp. 0:No 1:Yes (No ) Yes / No Warning oiltemp 60 Stop oil temp. 65
Drive motor Temp 0:No 1:Yes (No )
10.96
ATLET SERVICE MANUAL U - AC Power Plus
Pump motor temp 0:No 1:Yes (Yes) Speed reduction. 0:No 1:Yes (Yes) Batt. Level buzz 0:No 1:Yes (No ) Reach out creep 0:No 1:Yes (No ) Krocksensor 0:No 1:Yes (No ) Yes / No Impact warn.lim. 40 Impact horn lim. 200 Impactflashlim. 200 Impact stop lim. 200 Impact sup. lim. 200
Timeout log off 0:No 1:Yes (No ) Yes / No Logoff time (mi) 0
ATLET SERVICE MANUAL U - AC Power Plus
10.97
System supervis. 0:No 1:Yes (No ) Display logon-h. 0:No 1:Yes (No ) Transp. indicat. 0:No 1:Yes (No ) Battery shunt op 0:No 1:Yes (No ) Extra 1 Temp. 0:No 1:Yes (No )
Yes / No Warning Extra T1 60 Stop Extra T1 65
Extra 2 Temp. 0:No 1:Yes (No )
Yes / No Warning extra T2 100 Stop Extra T2 120
Summer time 0:No 1:Yes (Yes)
10.98
ATLET SERVICE MANUAL U - AC Power Plus
Show hight 0:No 1:Yes (Yes)
Yes / No Feet inch height 0:No 1:Yes (No )
Seat switch opt. 0:No 1:Yes (No ) Wheel ind. opt. 0:No 1:Yes (Yes)
ATLET SERVICE MANUAL U - AC Power Plus
10.99
3.4.1.X
AC driver X
AC Parameters AC driver X Maximum speed --Creep speed --Acceleration dri --Curr Limit Drive --Reduc.brakes dri --Reverse braking --Pedal braking --Max backw. speed --Max pump speed --Max lower speed --Acc. pump --Hydralic spare --Steering spare 1 --Steering spare 2 ---
10.100
ATLET SERVICE MANUAL U - AC Power Plus
X can be 1 to 4. All values are from 0 to 100 percent of machine max performance
Select joystick
3.4.2.X
Channel : xxxxx: 1. Lyft 2 2 3 3 4 4
Channel : zzzzz 1. Lower 2 Extend 3 Tiltout 4 ShiftR 5 Open
Channel xxxxx Press Enter yyyyy
max level ---
yyyyy
min level ---
zzzzz
max level ---
zzzzz
min level ---
Channel can be selected by digit 1 to 5 or by touching the lever.
Channel : yyyyy 1. Raise 2 Retract 3 Tiltin 4 ShiftL 5 Close
Joyst. deadzone: --yyyyyy acc: --yyyyyy ret.: --zzzzzz acc: --zzzzzz ret.: --Fetch B./Scalef. --Pos. Motor close --Neg. Motor close ---
ATLET SERVICE MANUAL U - AC Power Plus
10.101
3.4.3
Set battery
Select setting: 3:Sätta batteri Select 48V batt. 0:No 1:Yes (Yes) Measured B+ (mV) ----Battery size(Ah) --Pump size
(kW) ---
Utilisation (%) --Chassis const. 1 --Chassis const. 2 --Low batt. level --Lift stop level --Spare 1 ---
3.4.4
10.102
Set levelsyst
Select setting 4:Set levelsyst
ATLET SERVICE MANUAL U - AC Power Plus
See M403, M404, M405 resp. M406.
3.7.5.1
Read data
Acquisition menu 1:Read data Forward 0 0
3.7.5.2
Print data
Note 4
0
Acquisition menu 2: Print data DP1000 printer ? 0:No 1:Yes (No ) Printing…… please wait !
3.7.5.X
Setup acq. N
Acquisition menu X:Setup acq. N Pin to acquire ? -
N is channel between 1 and 5 See M330 for more info.
Size of bin(.1s) Invert 0=No 1=Ye --
3.7.7
Test any outp
Select test 7: Test any outp Outputno: (0=ex) 0 Exit ? --------------0:Exit 1:Toggle
On line 1 selected output is diplayed.
ATLET SERVICE MANUAL U - AC Power Plus
10.103
3.7.8
Show inputs
Select test 8:Show inputs Se Not 12 Dig.Input XC2:12 XXXXXXXXXXXXXX
3.8.3
Read service
Log book menu 3:Read service Func. not avail. Press Enter
3.8.4
Sign service
Log book menu 4:Signera serv. Func. not avail. Press Enter
3.8.8
NVR upload.
Log book menu 8:NVR upload Load std. NVR ? 0:No 1:Yes (No ) Yes / No Loading !!!!!!!
10.104
ATLET SERVICE MANUAL U - AC Power Plus
Terminated automaticly.
3.9
Set all def.
ATLET service 9:Set all def. Are you sure ? 0:No 1:Yes (No ) Yes/ No Terminated automaticly.
ATLET SERVICE MANUAL U - AC Power Plus
10.105
4.1
Custom service 1: Unlock
Unlock
Code : ??????? Code OK Code : Id not found.
4.2
Communication
Custom service 2:Communication
DL2 Press Enter PSION COMM.
4.3.X
Print yyyyy
Func. not avail. A Press Enter
Print custom X:Print yyyyy DP1000 printer? 0:No 1:Yes (No ) Printing…… please wait !
10.106
ATLET SERVICE MANUAL U - AC Power Plus
X 1 2 3 4 5 6 7 8
yyyyyyy counters cus.log tmp.log serv.log err.log settings spare all log
4.4.1
Cust. counter
Read custom 1: Cust counter ID ON
N ÅÅMMDD HH:MM
ID N OFF ÅÅMMDD HH:MM ID Drive:
N
ID Lift:
N
ID N Logged:
N: user ID Time for first logon Time for last logoff.
-.--h
Sum of driving time
-.--h
Sum of liftting time
-.--h
Sum of logged on time.
more ID
4.5
Reset custom
Custom service 5: Reset custom Code : ??????? code OK
4.5.0
Code : Id not found. 4
ATLET SERVICE MANUAL U - AC Power Plus
10.107
6
Service menu 6: Driver param
Driver param
Number of digits depends on setting
User id: ? Number of digits depends on setting
Valid ID ? Code
Id not found *
: ****
Valid code ?
Id not found
Maximum speed --Acceleration dri --Reduc.brakes dri --Reverse braking --Hydralic spare --Steering spare 1 --Steering spare 2 ---
10.108
ATLET SERVICE MANUAL U - AC Power Plus
****
All values are from 0 to 100 percent of machine max performance
Note Description 1
The number of ? are the same as Id-length set in 3.1.8
2
The number of ? are the same as password-length set in 3.1.8
3
Select driver category from 1 to 4 and make settings in 3.4.1.X
4
Stepping is done with the arrow buttons step by step, with numbers 1..5 to beginning of data of each channel, H-button to exit. See M330 for more details.
5
Time setting: The keys Ent and down displays one more digit every time they are pressed. Up arrow displays one less digit every time it is pressed. Digits are entered as values. Format is: HH:MM:SS HH Hours MM Minutes SS Seconds
6
Date setting: The keys Ent and down displays one more digit every time they are pressed. Up arrow displays one less digit every time it is pressed. Digits are entered as values. Formatet är: DD:MM:YYYY DD Day MM Month YYYY Year
7
Date format: 1: dd-mon-yy 2: dd-mm-yyyy 3: mm-dd-yyyy 4: yyyy-mm-dd
ATLET SERVICE MANUAL U - AC Power Plus
10.109
8
Drive input-symbols: UNS/URF/UTF SaAFdBdMFP LoFHiFS1S2 Sa: Safety switch ( Left foot ) A Aisle Fd: Forward switch Bd: Reverse switch M: Fuse drive regulator F: Fuse pump regulator P: Fuse power-steering LoF: Low fork height ( 1/2 meter ) HiF: High fork height (3 meter )
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